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KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL SEN06202-12 – PDF DOWNLOAD
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KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL SEN06202-12 – PDF DOWNLOAD
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KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL SEN06202-12 – PDF DOWNLOAD
Language : English
Pages : 2090
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL SEN06202-12 – PDF DOWNLOAD
Cover............................................................................................................................................................................................. 1 00 Index and foreword ............................................................................................................................................................................ 3 Index ........................................................................................................................................................................................ 4 Foreword, safety and general information ..................................................................................................................................................... 19 Important safety notice .................................................................................................................................................................. 19 How to read the shop manual .............................................................................................................................................................. 26 Explanation of terms for maintenance standard ............................................................................................................................................ 28 Handling equipment of fuel system devices ................................................................................................................................................ 30 Handling of intake system parts .......................................................................................................................................................... 31 Handling of hydraulic equipment .......................................................................................................................................................... 32 Method of disconnecting and connecting of push-pull type coupler ......................................................................................................................... 34 Handling of electrical equipment ......................................................................................................................................................... 37 How to read electric wire code ........................................................................................................................................................... 45 Precautions when performing operation .................................................................................................................................................... 48 Practical use of KOMTRAX ................................................................................................................................................................. 53 Standard tightening torque table ......................................................................................................................................................... 54 List of abbreviation ..................................................................................................................................................................... 60 Conversion table ......................................................................................................................................................................... 65 01 Specification ................................................................................................................................................................................. 71 Table of contents ............................................................................................................................................................................ 72 Specifications ............................................................................................................................................................................... 73 Specification drawing .................................................................................................................................................................... 73 Specifications ........................................................................................................................................................................... 77 Weight table ............................................................................................................................................................................. 87 Table of fuel, coolant, and lubricants ................................................................................................................................................... 91 10 Structure and function ........................................................................................................................................................................ 93 Table of contents ............................................................................................................................................................................ 94 Engine and cooling system .................................................................................................................................................................... 96 Engine related parts ..................................................................................................................................................................... 96 KVGT ..................................................................................................................................................................................... 98 EGR system piping drawing ................................................................................................................................................................ 105 EGR system circuit diagram ............................................................................................................................................................... 107 EGR valve ................................................................................................................................................................................ 109 EGR cooler ............................................................................................................................................................................... 111 KCCV layout drawing ...................................................................................................................................................................... 112 KCCV ventilator .......................................................................................................................................................................... 114 KDPF ..................................................................................................................................................................................... 116 Cooling system ........................................................................................................................................................................... 120 Cooling fan motor ........................................................................................................................................................................ 122 Power train .................................................................................................................................................................................. 132 Power train system ....................................................................................................................................................................... 132 Layout of power train parts .............................................................................................................................................................. 134 Damper ................................................................................................................................................................................... 135 HST pump ................................................................................................................................................................................. 136 HST motor1 ............................................................................................................................................................................... 149 HST motor2 ............................................................................................................................................................................... 151 Transfer ................................................................................................................................................................................. 156 Clutch solenoid valve .................................................................................................................................................................... 163 Drive shaft .............................................................................................................................................................................. 165 Axle ..................................................................................................................................................................................... 166 Differential ............................................................................................................................................................................. 168 Torque proportional differential ......................................................................................................................................................... 172 Limited slip differential ................................................................................................................................................................ 174 Final drive .............................................................................................................................................................................. 179 Steering system .............................................................................................................................................................................. 181 Layout of steering devices ............................................................................................................................................................... 181 Steering column .......................................................................................................................................................................... 182 Priority valve ........................................................................................................................................................................... 183 Cushion valve ............................................................................................................................................................................ 187 Emergency steering valve ................................................................................................................................................................. 188 Orbitrol valve ........................................................................................................................................................................... 191 Brake system ................................................................................................................................................................................. 197 Layout of brake parts .................................................................................................................................................................... 197 Brake accumulator charge valve ........................................................................................................................................................... 199 Brake valve .............................................................................................................................................................................. 204 Brake accumulator ........................................................................................................................................................................ 208 Slack adjuster ........................................................................................................................................................................... 209 Brake .................................................................................................................................................................................... 211 Parking brake control .................................................................................................................................................................... 214 Parking brake ............................................................................................................................................................................ 215 Parking brake solenoid valve ............................................................................................................................................................. 216 Undercarriage and frame ...................................................................................................................................................................... 218 Axle mount ............................................................................................................................................................................... 218 Center hinge pin ......................................................................................................................................................................... 220 Tire ..................................................................................................................................................................................... 221 Hydraulic system ............................................................................................................................................................................. 223 Hydraulic component layout ............................................................................................................................................................... 223 Work equipment control ................................................................................................................................................................... 225 Hydraulic tank ........................................................................................................................................................................... 226 Double type gear pump .................................................................................................................................................................... 229 Steering and work equipment pump ......................................................................................................................................................... 230 Control valve ............................................................................................................................................................................ 242 CLSS ..................................................................................................................................................................................... 252 Hydraulic circuit diagram and names of valves ............................................................................................................................................ 256 Self-pressure reducing valve ............................................................................................................................................................. 269 Work equipment PPC valve ................................................................................................................................................................. 274 Work equipment lock solenoid valve ....................................................................................................................................................... 282 PPC circuit accumulator .................................................................................................................................................................. 283 ECSS accumulator ......................................................................................................................................................................... 284 Work equipment ............................................................................................................................................................................... 285 Work equipment linkage ................................................................................................................................................................... 285 Bucket ................................................................................................................................................................................... 286 Cab and its attachments ...................................................................................................................................................................... 287 ROPS cab ................................................................................................................................................................................. 287 Cab mount ................................................................................................................................................................................ 289 Electrical system ............................................................................................................................................................................ 290 Engine control system .................................................................................................................................................................... 290 Preheating system ........................................................................................................................................................................ 293 Engine output limit function ............................................................................................................................................................. 295 Automatic warm-up function ............................................................................................................................................................... 296 Parking brake control system ............................................................................................................................................................. 297 System operating lamp function ........................................................................................................................................................... 301 Battery disconnect switch function ....................................................................................................................................................... 302 HST controller system .................................................................................................................................................................... 304 Machine monitor system ................................................................................................................................................................... 344 Rearview monitor system .................................................................................................................................................................. 365 KOMTRAX system ........................................................................................................................................................................... 368 System component parts ................................................................................................................................................................... 371 Sensor ................................................................................................................................................................................... 394 20 Standard value tables ......................................................................................................................................................................... 415 Table of contents ............................................................................................................................................................................ 416 Standard service value table ................................................................................................................................................................. 417 Standard value table for engine .......................................................................................................................................................... 417 Standard value table for machine ......................................................................................................................................................... 419 Standard value table for electrical system ............................................................................................................................................... 431 30 Testing and adjusting ......................................................................................................................................................................... 441 Table of contents ............................................................................................................................................................................ 442 Related information on testing and adjusting ................................................................................................................................................. 444 Tools for testing and adjusting .......................................................................................................................................................... 444 Sketch of tools for testing and adjusting ................................................................................................................................................ 450 Engine and cooling system .................................................................................................................................................................... 451 Testing engine speed ..................................................................................................................................................................... 451 Testing boost pressure ................................................................................................................................................................... 452 Testing exhaust gas temperature .......................................................................................................................................................... 454 Testing exhaust gas color ................................................................................................................................................................ 455 Test mass air flow and temperature sensor................................................................................................................................................. 457 Testing and adjusting valve clearance .................................................................................................................................................... 459 Testing compression pressure ............................................................................................................................................................. 462 Testing blowby pressure .................................................................................................................................................................. 466 Testing engine oil pressure .............................................................................................................................................................. 467 Testing EGR valve and KVGT oil pressures ................................................................................................................................................. 468 Testing fuel pressure .................................................................................................................................................................... 469 Testing fuel discharge, return and leakage ............................................................................................................................................... 474 Bleeding air from fuel system ............................................................................................................................................................ 479 Testing fuel circuit for leakage ......................................................................................................................................................... 481 Handling cylinder cutout mode operation .................................................................................................................................................. 482 Handling no-injection cranking operation ................................................................................................................................................. 483 Testing of KDPF and muffler stack for looseness and damage ............................................................................................................................... 484 Testing of installed condition of cylinder heads and manifolds ........................................................................................................................... 485 Testing engine piping for damage and looseness ........................................................................................................................................... 486 Testing and adjusting air conditioner compressor belt tension ............................................................................................................................ 487 Check alternator belt, replace ........................................................................................................................................................... 488 Check auto-tensioner, replace ............................................................................................................................................................ 490 Writing compensation amount for soot accumulation caused by ash on engine controller ..................................................................................................... 492 Power train .................................................................................................................................................................................. 494 Testing oil leakage from axle final drive ................................................................................................................................................ 494 Testing drive shaft for looseness, backlash, and damage .................................................................................................................................. 495 Testing accelerator pedal ................................................................................................................................................................ 496 Testing and adjusting HST oil pressure ................................................................................................................................................... 497 Testing transfer clutch control pressure ................................................................................................................................................. 500 Steering system .............................................................................................................................................................................. 501 Testing directional lever ................................................................................................................................................................ 501 Testing steering wheel ................................................................................................................................................................... 502 Testing work equipment control lever ..................................................................................................................................................... 504 Testing and adjusting steering circuit oil pressure ...................................................................................................................................... 506 Bleeding air from steering cylinder circuit .............................................................................................................................................. 508 Brake system ................................................................................................................................................................................. 509 Testing brake pedal ...................................................................................................................................................................... 509 Testing braking performance .............................................................................................................................................................. 510 Testing and adjusting of accumulator charge pressure ..................................................................................................................................... 511 Testing wheel brake oil pressure ......................................................................................................................................................... 513 Testing lowering of wheel brake pressure ................................................................................................................................................. 514 Testing wear of wheel brake disc ......................................................................................................................................................... 516 Bleeding air from wheel brake circuit .................................................................................................................................................... 517 Releasing remaining pressure in brake accumulator circuit ................................................................................................................................ 518 Testing parking brake performance ........................................................................................................................................................ 519 Testing wear of parking brake disc ....................................................................................................................................................... 520 Testing parking brake release pressure ................................................................................................................................................... 521 Method of releasing parking brake manually ............................................................................................................................................... 522 Hydraulic system ............................................................................................................................................................................. 523 Testing cooling fan speed ................................................................................................................................................................ 523 Testing cooling fan pump circuit oil pressure ............................................................................................................................................ 524 Bleeding air from hydraulic fan circuit .................................................................................................................................................. 526 Testing and adjusting work equipment PPC oil pressure .................................................................................................................................... 527 Testing and adjusting work equipment oil pressure ........................................................................................................................................ 529 Bleeding air from work equipment circuit ................................................................................................................................................. 533 Releasing remaining pressure from work equipment circuit ................................................................................................................................. 534 Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas .................................................................................. 536 Work equipment ............................................................................................................................................................................... 540 Testing and adjusting bucket positioner and bucket proximity switch ...................................................................................................................... 540 Testing and adjusting boom position detection lever ...................................................................................................................................... 542 Electrical system ............................................................................................................................................................................ 543 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ................................................................................................... 543 Special functions of machine monitor ..................................................................................................................................................... 544 Adjusting rearview camera angle .......................................................................................................................................................... 623 Handling voltage circuit of engine controller ............................................................................................................................................ 624 Handling battery disconnect switch ....................................................................................................................................................... 625 Testing diodes ........................................................................................................................................................................... 626 Pm clinic .................................................................................................................................................................................... 627 Pm Clinic service ........................................................................................................................................................................ 627 Check sheet .............................................................................................................................................................................. 628 40 Troubleshooting ............................................................................................................................................................................... 635 Table of contents ............................................................................................................................................................................ 636 Related information on troubleshooting ....................................................................................................................................................... 645 Troubleshooting points ................................................................................................................................................................... 645 Sequence of events in troubleshooting .................................................................................................................................................... 647 Checks before troubleshooting ............................................................................................................................................................ 649 Inspection procedure before troubleshooting .............................................................................................................................................. 651 Preparation for troubleshooting of electrical system ..................................................................................................................................... 668 Classification and procedures for troubleshooting ........................................................................................................................................ 674 Symptom and troubleshooting numbers ...................................................................................................................................................... 677 Information in troubleshooting table ..................................................................................................................................................... 680 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit .................................................................................................. 682 Connector list and layout ................................................................................................................................................................ 685 Connector contact identification ......................................................................................................................................................... 699 T-branch box and T-branch adapter table .................................................................................................................................................. 738 Fuse location table ...................................................................................................................................................................... 743 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ............................................................................................................................ 746 Precautions when performing troubleshooting of machine monitor ........................................................................................................................... 749 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit .................................................................................................. 751 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .......................................................................................................... 756 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) .............................................................................................. 757 Failure codes table ...................................................................................................................................................................... 758 Troubleshooting by failure code (Display of code) ............................................................................................................................................ 770 Failure code [2F00MA] Failure of Parking Brake Circuit ................................................................................................................................... 770 Failure code [2F00MB] Malfunction of Parking Brake ....................................................................................................................................... 773 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................................................................................................... 775 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ................................................................................................................................ 777 Failure code [6091NX] HST Oil Filter Clogging ............................................................................................................................................ 779 Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ......................................................................................................................... 781 Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. .......................................................................................................................... 783 Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ............................................................................................................................. 785 Failure code [879AKA] A/C Inner Sensor Open Circuit ...................................................................................................................................... 787 Failure code [879AKB] A/C Inner Sensor Short Circuit ..................................................................................................................................... 788 Failure code [879BKA] A/C Outer Sensor Open Circuit ...................................................................................................................................... 789 Failure code [879BKB] A/C Outer Sensor Short Circuit ..................................................................................................................................... 790 Failure code [879CKA] Ventilating Sensor Open Circuit .................................................................................................................................... 791 Failure code [879CKB] Ventilating Sensor Short Circuit ................................................................................................................................... 792 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................................................................................................. 793 Failure code [879EMC] Ventilation Damper Abnormality ..................................................................................................................................... 794 Failure code [879FMC] Air Mix Damper Abnormality ......................................................................................................................................... 795 Failure code [989L00] Engine Controller Lock Caution 1 ................................................................................................................................... 796 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................................................................................... 797 Failure code [989N00] Engine Controller Lock Caution 3 ................................................................................................................................... 798 Failure code [A1U0N3] HC Desorb Request 1 ................................................................................................................................................ 799 Failure code [A1U0N4] HC Desorb Request 2 ................................................................................................................................................ 801 Failure code [AA10NX] Air Cleaner Clogging ............................................................................................................................................... 803 Failure code [AB00KE] Charge Voltage Low ................................................................................................................................................. 805 Failure code [AB00KY] Hot Short of Alternator R Terminal ................................................................................................................................. 806 Failure code [B@BAZG] Eng Oil Press Low .................................................................................................................................................. 807 Failure code [B@BAZK] Engine Oil Level Low ............................................................................................................................................... 808 Failure code [B@BCNS] Eng Water Overheat ................................................................................................................................................. 810 Failure code [B@BCZK] Eng Water Level Low ................................................................................................................................................ 811 Failure code [B@CRNS] HST Oil Temp. Overheat ............................................................................................................................................. 813 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................................................................................................... 814 Failure code [CA122] Chg Air Press Sensor High Error ..................................................................................................................................... 815 Failure code [CA123] Chg Air Press Sensor Low Error ...................................................................................................................................... 817 Failure code [CA131] Throttle Sensor High Error .......................................................................................................................................... 819 Failure code [CA132] Throttle Sensor Low Error ........................................................................................................................................... 821 Failure code [CA144] Coolant Temp Sens High Error ........................................................................................................................................ 823 Failure code [CA145] Coolant Temp Sens Low Error ......................................................................................................................................... 825 Failure code [CA153] Chg Air Temp Sensor High Error ...................................................................................................................................... 827 Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................................................................................................... 829 Failure code [CA187] Sensor 2 Supply Volt Low Error ...................................................................................................................................... 831 Failure code [CA221] Ambient Press Sensor High Error ..................................................................................................................................... 833 Failure code [CA222] Ambient Press Sensor Low Error ...................................................................................................................................... 835 Failure code [CA227] Sensor 2 Supply Volt High Error ..................................................................................................................................... 837 Failure code [CA234] Eng Overspeed ....................................................................................................................................................... 838 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................................................................................................... 839 Failure code [CA239] Ne Speed Sens Supply Volt High Error ................................................................................................................................ 840 Failure code [CA271] IMV/PCV1 Short Error ................................................................................................................................................ 841 Failure code [CA272] IMV/PCV1 Open Error ................................................................................................................................................. 843 Failure code [CA295] Ambient Press Sens In Range Error ................................................................................................................................... 845 Failure code [CA322] Inj #1(L#1) Open/Short Error ........................................................................................................................................ 846 Failure code [CA323] Inj #5(L#5) Open/Short Error ........................................................................................................................................ 848 Failure code [CA324] Inj #3(L#3) Open/Short Error ........................................................................................................................................ 850 Failure code [CA325] Inj #6(L#6) Open/Short Error ........................................................................................................................................ 852 Failure code [CA331] Inj #2(L#2) Open/Short Error ........................................................................................................................................ 854 Failure code [CA332] Inj #4(L#4) Open/Short Error ........................................................................................................................................ 856 Failure code [CA343] ECM Critical Internal Failure ....................................................................................................................................... 858 Failure code [CA351] Injectors Drive Circuit Error ....................................................................................................................................... 859 Failure code [CA352] Sensor 1 Supply Volt Low Error ...................................................................................................................................... 860 Failure code [CA356] Mass Air Flow Sensor High Error ..................................................................................................................................... 862 Failure code [CA357] Mass Air Flow Sensor Low Error ...................................................................................................................................... 864 Failure code [CA386] Sensor 1 Supply Volt High Error ..................................................................................................................................... 866 Failure code [CA428] Water in Fuel Sensor High Error ..................................................................................................................................... 867 Failure code [CA429] Water in Fuel Sensor Low Error ...................................................................................................................................... 869 Failure code [CA431] Idle Validation Sw Error ............................................................................................................................................ 871 Failure code [CA432] Idle Validation Process Error ....................................................................................................................................... 874 Failure code [CA435] Eng Oil Press Sw Error .............................................................................................................................................. 877 Failure code [CA441] Battery Voltage Low Error ........................................................................................................................................... 878 Failure code [CA442] Battery Voltage High Error .......................................................................................................................................... 880 Failure code [CA449] Rail Press Very High Error .......................................................................................................................................... 881 Failure code [CA451] Rail Press Sensor High Error ........................................................................................................................................ 882 Failure code [CA452] Rail Press Sensor Low Error ......................................................................................................................................... 884 Failure code [CA488] Chg Air Temp High Torque Derate ..................................................................................................................................... 886 Failure code [CA515] Rail Press Sens Sup Volt High Error ................................................................................................................................. 887 Failure code [CA516] Rail Press Sens Sup Volt Low Error .................................................................................................................................. 889 Failure code [CA553] Rail Press High Error ............................................................................................................................................... 891 Failure code [CA555] Crankcase Press High Error 1 ........................................................................................................................................ 892 Failure code [CA556] Crankcase Press High Error 2 ........................................................................................................................................ 893 Failure code [CA559] Rail Press Low Error ................................................................................................................................................ 894 Failure code [CA595] Turbo Speed High Error 2 ............................................................................................................................................ 896 Failure code [CA687] Turbo Speed Low Error ............................................................................................................................................... 897 Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................................................................................... 899 Failure code [CA691] Intake Air Temp Sens High Error ..................................................................................................................................... 901 Failure code [CA692] Intake Air Temp Sens Low Error ...................................................................................................................................... 903 Failure code [CA697] ECM Internal Temp Sensor High Error ................................................................................................................................. 905 Failure code [CA698] ECM Int Temp Sensor Low Error ....................................................................................................................................... 906 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..................................................................................................................................... 907 Failure code [CA778] Eng Bkup Speed Sensor Error ......................................................................................................................................... 909 Failure code [CA1117] Persistent Data Lost Error ......................................................................................................................................... 914 Failure code [CA1664] KDOC Malfunction ................................................................................................................................................... 915 Failure code [CA1691] Regeneration Ineffective ........................................................................................................................................... 918 Failure code [CA1695] Sensor 5 Supply Volt High Error .................................................................................................................................... 921 Failure code [CA1696] Sensor 5 Supply Volt Low Error ..................................................................................................................................... 922 Failure code [CA1843] Crankcase Press Sens High Error .................................................................................................................................... 924 Failure code [CA1844] Crankcase Press Sens Low Error ..................................................................................................................................... 926 Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................................................................................................... 928 Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................................................................................................... 930 Failure code [CA1883] KDPF Delta P Sens In Range Error ................................................................................................................................... 932 Failure code [CA1921] KDPF Soot Load High Error 1 ........................................................................................................................................ 936 Failure code [CA1922] KDPF Soot Load High Error 2 ........................................................................................................................................ 939 Failure code [CA1942] Crankcase Press Sens In Range Error ................................................................................................................................ 944 Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................................................................................................... 945 Failure code [CA2185] Throt Sensor Sup Volt High Error ................................................................................................................................... 948 Failure code [CA2186] Throt Sensor Sup Volt Low Error .................................................................................................................................... 950 Failure code [CA2249] Rail Press Very Low Error .......................................................................................................................................... 952 Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................................................................................................... 953 Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................................................................................................... 955 Failure code [CA2288] Turbo Speed High Error 1 ........................................................................................................................................... 958 Failure code [CA2311] IMV Solenoid Error ................................................................................................................................................. 959 Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................................................................................................... 960 Failure code [CA2353] EGR Valve Solenoid Short Error ..................................................................................................................................... 962 Failure code [CA2357] EGR Valve Servo Error .............................................................................................................................................. 964 Failure code [CA2373] Exhaust Manifold Press Sens High error ............................................................................................................................. 965 Failure code [CA2374] Exhaust Manifold Press Sens Low error .............................................................................................................................. 967 Failure code [CA2375] EGR Orifice Temp Sens High Error ................................................................................................................................... 969 Failure code [CA2376] EGR Orifice Temp Sens Low Error .................................................................................................................................... 971 Failure code [CA2381] KVGT Pos Sens High Error ........................................................................................................................................... 973 Failure code [CA2382] KVGT Pos Sens Low Error ............................................................................................................................................ 975 Failure code [CA2383] KVGT Solenoid Open Error ........................................................................................................................................... 978 Failure code [CA2386] KVGT Solenoid Short Error .......................................................................................................................................... 980 Failure code [CA2387] KVGT Servo Error ................................................................................................................................................... 982 Failure code [CA2554] Exh Manifold Press Sens In Range Error ............................................................................................................................. 987 Failure code [CA2555] Grid Htr Relay Volt Low Error ...................................................................................................................................... 990 Failure code [CA2556] Grid Htr Relay Volt High Error ..................................................................................................................................... 992 Failure code [CA2637] KDOC Face Plugging ................................................................................................................................................. 994 Failure code [CA2639] Manual Stationary Regeneration Request ............................................................................................................................. 996 Failure code [CA2961] EGR Orifice Temp High Error 1 ...................................................................................................................................... 999 Failure code [CA2973] Chg Air Press Sensor In Range Error ................................................................................................................................1000 Failure code [CA3133] KDPF Outlet Press Sens High Error ..................................................................................................................................1001 Failure code [CA3134] KDPF Outlet Press Sens Low Error ...................................................................................................................................1003 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ..............................................................................................................................1005 Failure code [CA3251] KDOC Inlet Temp High Error .........................................................................................................................................1009 Failure code [CA3253] KDOC Temp Error - Non Regeneration .................................................................................................................................1012 Failure code [CA3254] KDOC Outlet Temp High Error 1 ......................................................................................................................................1016 Failure code [CA3255] KDPF Temp Error - Non Regeneration .................................................................................................................................1019 Failure code [CA3256] KDPF Outlet Temp High Error 1 ......................................................................................................................................1023 Failure code [CA3311] KDOC Outlet Temp High Error 2 ......................................................................................................................................1026 Failure code [CA3312] KDPF Outlet Temp High Error 2 ......................................................................................................................................1030 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...................................................................................................................................1034 Failure code [CA3314] KDOC Inlet Temp Sens High Error ....................................................................................................................................1037 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ................................................................................................................................1040 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....................................................................................................................................1044 Failure code [CA3317] KDOC Outlet Temp Sens High Error ...................................................................................................................................1047 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...............................................................................................................................1050 Failure code [CA3319] KDPF Outlet Temp Sens High Error ...................................................................................................................................1054 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....................................................................................................................................1057 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...............................................................................................................................1060 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...........................................................................................................................1064 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ............................................................................................................................1066 Failure code [CA3741] Rail Press Valve Trip Error ........................................................................................................................................1068 Failure code [D110L4] Disconnection of Battery Relay Signal ..............................................................................................................................1069 Failure code [D160KA] Disconnection of Backup Lamp Relay Output ..........................................................................................................................1071 Failure code [D160KY] Hot Short of Backup Lamp Relay Output ..............................................................................................................................1073 Failure code [D191KA] Disconnection of Neutral Output Relay ..............................................................................................................................1075 Failure code [D191KB] Ground Fault of Neutral Output Relay ...............................................................................................................................1077 Failure code [D191KY] Hot Short of Neutral Output Relay ..................................................................................................................................1079 Failure code [D192KA] Disconnection of ECSS Solenoid .....................................................................................................................................1081 Failure code [D192KB] Ground Fault of ECSS Solenoid ......................................................................................................................................1083 Failure code [D192KY] Hot Short of ECSS Solenoid .........................................................................................................................................1084 Failure code [D19JKZ] Personal Code Relay Abnormality ....................................................................................................................................1085 Failure code [D1B0KA] Disconnection of HST Safety Relay ..................................................................................................................................1087 Failure code [D1B0KB] Ground Fault of HST Safety Relay ...................................................................................................................................1089 Failure code [D1B0KY] Hot Short of HST Safety Relay ......................................................................................................................................1091 Failure code [D1B0MC] Malfunction of HST Safety Relay ....................................................................................................................................1093 Failure code [D1E6KA] Disconnection of Parking Brake Relay ...............................................................................................................................1094 Failure code [D1E6KB] Ground Fault of Parking Brake Relay ................................................................................................................................1096 Failure code [D1E6KY] Hot Short of Parking Brake Relay ...................................................................................................................................1098 Failure code [D5ZHKA] Failure of Key SW C Signal .........................................................................................................................................1100 Failure code [D5ZHKB] Key SW C Signal Short Circuit ......................................................................................................................................1102 Failure code [D5ZHL6] Disconnection of Key SW C ..........................................................................................................................................1104 Failure code [D811MC] KOMTRAX Error ......................................................................................................................................................1105 Failure code [D862KA] GPS Antenna Open Circuit ...........................................................................................................................................1106 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ..............................................................................................................................1107 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .............................................................................................................................1109 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ............................................................................................................................................1111 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..............................................................................................................................................1112 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...........................................................................................................................1114 Failure code [DAF0MB] Monitor ROM Abnormality ............................................................................................................................................1115 Failure code [DAF0MC] Monitor Error ......................................................................................................................................................1116 Failure code [DAF3KK] Controller Power Source Low (MON) ..................................................................................................................................1117 Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................................................................................................1119 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .............................................................................................................................1120 Failure code [DAFGMC] GPS Module Error ...................................................................................................................................................1121 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ..................................................................................................................................1122 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) .................................................................................................................................1124 Failure code [DAFQKR] CAN2 Discon (Monitor) ..............................................................................................................................................1126 Failure code [DAJ0KK] Controller Power Source Low (HST) ..................................................................................................................................1127 Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ...........................................................................................................................1130 Failure code [DAJ0MC] HST Con Error ......................................................................................................................................................1131 Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ..................................................................................................................................1132 Failure code [DAJ2KK] Solenoid Power Source Low (HST) ....................................................................................................................................1134 Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ............................................................................................................................1137 Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay .................................................................................................................................1139 Failure code [DAJ5KX] Failure of 5V Power Source 0 .......................................................................................................................................1141 Failure code [DAJ6KX] Failure of 5V Power Source 1 .......................................................................................................................................1143 Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) .............................................................................................................................1145 Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ..................................................................................................................................1146 Failure code [DAJLKB] Operating Lamp Short Circuit (HST) .................................................................................................................................1148 Failure code [DAJQKR] CAN2 Discon ( HST Con) .............................................................................................................................................1150 Failure code [DAJRKR] CAN1 Discon ( HST Con) .............................................................................................................................................1151 Failure code [DAJRMA] Inconsistency of Option Selection (HST) ............................................................................................................................1152 Failure code [DAZ9KQ] A/C Model Selection Abnormality ....................................................................................................................................1153 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...........................................................................................................................................1154 Failure code [DB2QKR] CAN2 Discon (Engine Con) ...........................................................................................................................................1155 Failure code [DB2RKR] CAN1 Discon (Engine Con) ...........................................................................................................................................1160 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...........................................................................................................................1164 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch .........................................................................................................................1166 Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ................................................................................................................................1168 Failure code [DDB6L4] Parking Brake Signal Malfunction ...................................................................................................................................1170 Failure code [DDD7KA] Failure of Variable Speed Control ..................................................................................................................................1173 Failure code [DDD7KY] Hot Short of Variable Speed Control ................................................................................................................................1175 Failure code [DDK3KA] FNR SW Input Signal Disconnection ..................................................................................................................................1177 Failure code [DDK3KB] FNR SW Input Signal Short Circuit ..................................................................................................................................1179 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...............................................................................................................................1181 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...............................................................................................................................1184 Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ............................................................................................................................1186 Failure code [DF10KA] Disconnection of Speed Range Input .................................................................................................................................1188 Failure code [DF10KB] Ground Fault of Speed Range Input ..................................................................................................................................1191 Failure code [DGH1KX] Out of Range of HST Oil Temp. Sensor ...............................................................................................................................1194 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor .............................................................................................................................1196 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ..................................................................................................................................1198 Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ..............................................................................................................................1200 Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ...........................................................................................................................1202 Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) .........................................................................................................................1204 Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ...........................................................................................................................1206 Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) .........................................................................................................................1208 Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) .............................................................................................................................1210 Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ...........................................................................................................................1212 Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ...........................................................................................................................1214 Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. .........................................................................................................................1216 Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ............................................................................................................................1218 Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ..........................................................................................................................1220 Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ............................................................................................................................1222 Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ..........................................................................................................................1224 Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ...........................................................................................................................1226 Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit .........................................................................................................................1228 Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ...........................................................................................................................1230 Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit .........................................................................................................................1232 Failure code [DHT8ZG] Steering Oil Pressure Low ..........................................................................................................................................1234 Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ...........................................................................................................................1235 Failure code [DJF1KA] Disconnection of Fuel Level Sensor .................................................................................................................................1237 Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................................................................................................1239 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ............................................................................................................................1242 Failure code [DK55L5] Failure of FNR Lever Potentio ......................................................................................................................................1244 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...............................................................................................................................1245 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) .............................................................................................................................1248 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...........................................................................................................................1251 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ................................................................................................................................1254 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ..............................................................................................................................1257 Failure code [DK70KA] Failure of inching sensor Circuit ..................................................................................................................................1260 Failure code [DK70KY] Hot Short of inching sensor Circuit ................................................................................................................................1263 Failure code [DKA0KA] Failure of Boom Angle Sensor .......................................................................................................................................1265 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .............................................................................................................................1267 Failure code [DKA0L0] Boom Angle Sensor Dislocation ......................................................................................................................................1269 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor .........................................................................................................................1271 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...............................................................................................................................1273 Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ...........................................................................................................................1274 Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ...........................................................................................................................1276 Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ...............................................................................................................................1278 Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ..............................................................................................................................1281 Failure code [DPQ1KR] LIN Discon (Switch Panel) ..........................................................................................................................................1283 Failure code [DPQ2KR] LIN Discon (LED Unit) ..............................................................................................................................................1286 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) .....................................................................................................................................1289 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...........................................................................................................................................1292 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ............................................................................................................................1294 Failure code [DV00KB] Ground Fault of Buzzer Output ......................................................................................................................................1296 Failure code [DW26KA] Disconnection of Motor 2 Solenoid ..................................................................................................................................1298 Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ...................................................................................................................................1300 Failure code [DW26KY] Hot Short of Motor 2 Solenoid ......................................................................................................................................1302 Failure code [DW4BKA] Disconnection of Parking Brake Valve ...............................................................................................................................1304 Failure code [DW4BKB] Ground Fault of Parking Brake Valve ................................................................................................................................1306 Failure code [DW4BKY] Hot Short of Parking Brake Valve ...................................................................................................................................1308 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ............................................................................................................................1309 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .........................................................................................................................1311 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ............................................................................................................................1313 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid .............................................................................................................................1314 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ..............................................................................................................................1316 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid .................................................................................................................................1318 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ............................................................................................................................1319 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) .............................................................................................................................1321 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ................................................................................................................................1323 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..........................................................................................................................1325 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...........................................................................................................................1327 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ..............................................................................................................................1329 Failure code [DX19KA] Disconnection of Motor 1 Solenoid ..................................................................................................................................1330 Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ...................................................................................................................................1332 Failure code [DX19KY] Hot Short of Motor 1 Solenoid ......................................................................................................................................1334 Failure code [DX20KA] Disconnection of Clutch Control Solenoid ...........................................................................................................................1336 Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ............................................................................................................................1338 Failure code [DX20KY] Hot Short of Clutch Control Solenoid ...............................................................................................................................1340 Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. .................................................................................................................................1342 Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ..................................................................................................................................1344 Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. .....................................................................................................................................1346 Failure code [DXH7KA] Disconnection of Reverse Solenoid ..................................................................................................................................1348 Failure code [DXH7KB] Ground Fault of Reverse Solenoid ...................................................................................................................................1350 Failure code [DXH7KY] Hot Short of Reverse Solenoid ......................................................................................................................................1352 Failure code [DXH8KA] Disconnection of Forward Solenoid ..................................................................................................................................1354 Failure code [DXH8KB] Ground Fault of Forward Solenoid ...................................................................................................................................1356 Failure code [DXH8KY] Hot Short of Forward Solenoid ......................................................................................................................................1358 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ............................................................................................................................1360 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) .............................................................................................................................1362 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ................................................................................................................................1364 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ............................................................................................................................1365 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) .............................................................................................................................1367 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ................................................................................................................................1369 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...............................................................................................................................1370 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal .............................................................................................................................1373 Failure code [J141N1] Steering Pump Over Run .............................................................................................................................................1375 Failure code [LA00L3] Failure of Fan Reverse .............................................................................................................................................1376 Failure code [M100N1] HST Pump Over Run ..................................................................................................................................................1377 Failure code [M400N1] HST Motor 1 Over Run ...............................................................................................................................................1378 Troubleshooting of electrical system (E-mode) ................................................................................................................................................1379 E-1 Engine does not start ................................................................................................................................................................1379 E-2 Manual preheating system does not work ...............................................................................................................................................1386 E-3 Automatic preheating system does not work ............................................................................................................................................1389 E-4 While preheating is working, preheating monitor does not light up ....................................................................................................................1391 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .........................................................................................................1393 E-6 LCD unit on machine monitor displays nothing .........................................................................................................................................1396 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ................................................................................................1398 E-8 LCD on machine monitor does not display properly .....................................................................................................................................1400 E-9 Meter unit display on machine monitor is abnormal ....................................................................................................................................1402 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ....................................................................................................................1405 E-11 Caution LED on machine monitor is abnormal ..........................................................................................................................................1408 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ............................................................................................1410 E-13 Two switches operation of switch panel on machine monitor does not function .........................................................................................................1412 E-14 Switch panel buzzer of machine monitor is abnormal ..................................................................................................................................1415 E-15 Rearview monitor does not light up or backlight flickers ............................................................................................................................1417 E-16 Rearview monitor images are not displayed clearly ...................................................................................................................................1420 E-17 Rearview monitor brightness cannot be adjusted ......................................................................................................................................1423 E-18 Night lighting lamp of rearview monitor is abnormal .................................................................................................................................1426 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ................................................................................................1428 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ..................................................................................1429 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light .......................................................................................1433 E-22 Air cleaner clogging indicator lamp does not light ..................................................................................................................................1435 E-23 Radiator coolant level caution lamp does not light ..................................................................................................................................1437 E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light .......................................................................1439 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 ....1440 E-26 Fuel level gauge does not indicate correct level ....................................................................................................................................1442 E-27 Seat belt caution lamp indication is abnormal .......................................................................................................................................1444 E-28 Horn does not sound .................................................................................................................................................................1445 E-29 Horn does not stop sounding .........................................................................................................................................................1448 E-30 Alarm buzzer does not sound .........................................................................................................................................................1450 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding .........................................................................................................1452 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 ................1453 E-33 Setting does not change while operating traction control switch .....................................................................................................................1455 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 .......................................................1457 E-35 Remote positioner does not work or cannot be released ...............................................................................................................................1460 E-36 Bucket positioner does not work or cannot be released ...............................................................................................................................1462 E-37 Direction selector (FNR) switch mode is not selected or not released ................................................................................................................1465 E-38 PZ auto tilt-in does not work .......................................................................................................................................................1467 E-39 Tracktion level does not display MAX when max traction switch is turned ON ..........................................................................................................1470 E-40 ECSS function cannot be selected or cannot be released ..............................................................................................................................1472 E-41 None of headlamp, clearance lamp, and tail lamp lights ..............................................................................................................................1474 E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out ..........................................................................................................1476 E-43 Both High and Low beams of headlamp do not light up or go out .......................................................................................................................1480 E-44 Low beam of headlamp does not light up or go out ....................................................................................................................................1484 E-45 High beam of headlamp does not light up or go out ...................................................................................................................................1486 E-46 Front working lamp does not light up or go out ......................................................................................................................................1488 E-47 Rear working lamp does not light up or go out .......................................................................................................................................1492 E-48 All of turn signal lamps and hazard lamps do not flash or go out ....................................................................................................................1496 E-49 Turn signal lamps do not flash or go out ............................................................................................................................................1499 E-50 Hazard lamp does not flash or go out ................................................................................................................................................1502 E-51 Brake lamp does not light or stays lighted ..........................................................................................................................................1505 E-52 Backup lamp does not light up or does not go out ....................................................................................................................................1508 E-53 Backup buzzer does not sound or continues to sound ..................................................................................................................................1511 E-54 Front wiper does not operate ........................................................................................................................................................1513 E-55 Rear wiper does not operate .........................................................................................................................................................1516 E-56 Window washer does not operate ......................................................................................................................................................1518 E-57 KOMTRAX system does not operate normally ............................................................................................................................................1521 Troubleshooting of hydraulic and mechanical system (H-mode) ..................................................................................................................................1523 Information described in troubleshooting table (H-mode) ..................................................................................................................................1523 System chart of hydraulic and mechanical systems .........................................................................................................................................1524 Failure mode and cause table .............................................................................................................................................................1526 H-1 Machine does not travel forward or backward ..........................................................................................................................................1532 H-2 Machine does not travel forward (Machine travels backward normally) ..................................................................................................................1535 H-3 Machine does not travel backward (Machine travels forward normally) ..................................................................................................................1536 H-4 Machine does not travel forward or backward fast .....................................................................................................................................1537 H-5 Machine does not travel forward fast (Machine travel backward fast) ..................................................................................................................1541 H-6 Machine does not travel backward fast (Machine travel forward fast) ..................................................................................................................1542 H-7 Machine lacks power neither when traveling forward nor backward ......................................................................................................................1543 H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ....................................................................................1546 H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ...................................................................................1547 H-10 Engine stalls during travel or engine speed drops significantly .....................................................................................................................1548 H-11 Steering wheel is too heavy to turn .................................................................................................................................................1549 H-12 Steering wheel is heavy to turn .....................................................................................................................................................1551 H-13 Machine sways or large shocks are made while machine turns ..........................................................................................................................1552 H-14 Machine unintentionally turns when machine travels ..................................................................................................................................1553 H-15 Wheel brakes do not work or are weak ................................................................................................................................................1554 H-16 Wheel brakes are not released or drag ...............................................................................................................................................1555 H-17 Parking brake does not work or it is weak ...........................................................................................................................................1556 H-18 Parking brake is not released or drags. .............................................................................................................................................1557 H-19 Boom does not rise ..................................................................................................................................................................1558 H-20 Boom moves slow or boom lacks lifting force .........................................................................................................................................1560 H-21 Rising boom slows down at certain height ............................................................................................................................................1562 H-22 Lift cylinders do not serve to hold bucket (bucket rises off ground) ................................................................................................................1563 H-23 Hydraulic drift of boom is large ....................................................................................................................................................1564 H-24 Boom moves up and down during operation .............................................................................................................................................1565 H-25 Bucket does not tilt back ...........................................................................................................................................................1566 H-26 Bucket moves slow or lacks tilt force ...............................................................................................................................................1568 H-27 Bucket decelerates during tilt-back operation .......................................................................................................................................1570 H-28 Bucket cylinder does not hold bucket on ground ......................................................................................................................................1571 H-29 Hydraulic drift of bucket is large ..................................................................................................................................................1572 H-30 Bucket tilts back and forth during carrying load ....................................................................................................................................1573 H-31 Boom and bucket control levers do not move smoothly and are heavy to move ...........................................................................................................1574 H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ..............................................................................................1575 H-33 Large shocks are made when work equipment starts to move and stops ..................................................................................................................1576 H-34 When certain work equipment is relieved hydraulically, other work equipment moves ...................................................................................................1577 H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ..............................................................................................................1578 H-36 Fan speed is abnormal (too high or low, or fan does not rotate) .....................................................................................................................1579 H-37 Unusual noise is heard from around fan ..............................................................................................................................................1581 Troubleshooting of engine (S-mode) ...........................................................................................................................................................1582 Information described in troubleshooting table (S mode) ..................................................................................................................................1582 S-1 Engine does not crank when starting switch is turned to START position ...............................................................................................................1583 S-2 Engine cranks but no exhaust smoke comes out .........................................................................................................................................1584 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .......................................................................................1585 S-4 Engine startability is poor ..........................................................................................................................................................1586 S-5 Engine does not pick up smoothly .....................................................................................................................................................1588 S-6 Engine stops during operation ........................................................................................................................................................1590 S-7 Engine runs rough or is unstable .....................................................................................................................................................1592 S-8 Engine lacks power ...................................................................................................................................................................1593 S-9 KDPF gets clogged in a short time ....................................................................................................................................................1595 S-10 Engine oil consumption is excessive .................................................................................................................................................1597 S-11 Engine oil becomes contaminated early ...............................................................................................................................................1598 S-12 Fuel consumption is excessive .......................................................................................................................................................1599 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....................................................................................................................1600 S-14 Oil pressure drops ..................................................................................................................................................................1601 S-15 Fuel mixes into engine oil ..........................................................................................................................................................1602 S-16 Water mixes into engine oil (milky) .................................................................................................................................................1603 S-17 Coolant temperature rises too high (overheating) ....................................................................................................................................1604 S-18 Unusual noise is heard ..............................................................................................................................................................1605 S-19 Vibration is excessive ..............................................................................................................................................................1606 S-20 Air cannot be bled from fuel circuit ................................................................................................................................................1608 S-21 Active regeneration is executed frequently ..........................................................................................................................................1609 S-22 Active regeneration takes time ......................................................................................................................................................1610 S-23 White smoke is exhausted during active regeneration .................................................................................................................................1611 50 Disassembly and assembly ......................................................................................................................................................................1613 Table of contents ............................................................................................................................................................................1614 Related information on disassembly and assembly ..............................................................................................................................................1616 How to read this manual ..................................................................................................................................................................1616 Coating materials list ...................................................................................................................................................................1618 Special tools list .......................................................................................................................................................................1622 Sketches of special tools ................................................................................................................................................................1627 Engine and cooling system ....................................................................................................................................................................1640 Removal and installation of supply pump assembly .........................................................................................................................................1640 Removal and installation of injector assembly ............................................................................................................................................1643 Removal and installation of cylinder head assembly .......................................................................................................................................1653 Removal and installation of engine hood assembly .........................................................................................................................................1667 Removal and installation of radiator core assembly .......................................................................................................................................1669 Removal and installation of aftercooler ..................................................................................................................................................1671 Removal and installation of hydraulic oil cooler .........................................................................................................................................1672 Removal and installation of engine assembly ..............................................................................................................................................1673 Removal and installation of engine front oil seal ........................................................................................................................................1681 Removal and installation of engine rear oil seal .........................................................................................................................................1684 Removal and installation of cooling fan and fan motor assembly ...........................................................................................................................1687 Removal and installation of KDPF assembly ................................................................................................................................................1689 Disassembly and assembly of KDPF assembly ................................................................................................................................................1692 Removal and installation of KCCV assembly ................................................................................................................................................1701 Removal and installation of air cleaner assembly .........................................................................................................................................1702 Removal and installation of KVGT assembly ................................................................................................................................................1703 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ...............................................................................................................1706 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ..............................................................................................................1708 Removal and installation of alternator belt ..............................................................................................................................................1710 Removal and installation of fuel tank assembly ...........................................................................................................................................1711 Power train ..................................................................................................................................................................................1714 Removal and installation of transfer assembly ............................................................................................................................................1714 Disassembly and assembly of transfer assembly ............................................................................................................................................1719 Removal and installation of front axle assembly ..........................................................................................................................................1751 Removal and installation of rear axle assembly ...........................................................................................................................................1753 Disassembly and assembly of axle housing assembly ........................................................................................................................................1756 Disassembly and assembly of differential assembly ........................................................................................................................................1768 Undercarriage and frame ......................................................................................................................................................................1791 Removal and installation of center hinge pin .............................................................................................................................................1791 Removal and installation of counterweight assembly .......................................................................................................................................1800 Hydraulic system .............................................................................................................................................................................1804 Removal and installation of hydraulic tank assembly ......................................................................................................................................1804 Removal and installation of control valve assembly .......................................................................................................................................1808 Disassembly and assembly of control valve assembly .......................................................................................................................................1812 Removal and installation of hydraulic pump assembly ......................................................................................................................................1815 Removal and installation of HST motor1 assembly ..........................................................................................................................................1820 Removal and installation of HST motor2 assembly ..........................................................................................................................................1822 Disassembly and assembly of hydraulic cylinder assembly ..................................................................................................................................1824 Work equipment ...............................................................................................................................................................................1831 Removal and installation of work equipment assembly ......................................................................................................................................1831 Cab and its attachments ......................................................................................................................................................................1837 Removal and installation of operator's cab and floor frame assembly ......................................................................................................................1837 Removal and installation of operator's cab glass (adhered glass) .........................................................................................................................1842 Removal and installation of operator's seat assembly .....................................................................................................................................1850 Removal and installation of seat belt ....................................................................................................................................................1852 Removal and installation of air conditioner unit assembly ................................................................................................................................1853 Removal and installation of air conditioner compressor ...................................................................................................................................1858 Removal and installation of air conditioner condenser ....................................................................................................................................1860 Electrical system ............................................................................................................................................................................1862 Removal and installation of machine monitor assembly .....................................................................................................................................1862 Removal and installation of engine controller assembly ...................................................................................................................................1864 Removal and installation of HST controller assembly ......................................................................................................................................1866 Removal and installation of air conditioner controller assembly ..........................................................................................................................1868 Removal and installation of monitor controller assembly ..................................................................................................................................1869 Removal and installation of mass air flow and temperature sensor .........................................................................................................................1871 Removal and installation of KOMTRAX terminal assembly ....................................................................................................................................1872 60 Maintenance standard ..........................................................................................................................................................................1873 Table of contents ............................................................................................................................................................................1874 Engine and cooling system ....................................................................................................................................................................1875 Engine related parts .....................................................................................................................................................................1875 Cooling fan motor ........................................................................................................................................................................1876 Power train ..................................................................................................................................................................................1878 Damper ...................................................................................................................................................................................1878 Transfer .................................................................................................................................................................................1879 Drive shaft ..............................................................................................................................................................................1886 Axle .....................................................................................................................................................................................1887 Differential .............................................................................................................................................................................1889 Limited slip differential ................................................................................................................................................................1893 Final drive ..............................................................................................................................................................................1895 Steering system ..............................................................................................................................................................................1897 Steering column ..........................................................................................................................................................................1897 Priority valve ...........................................................................................................................................................................1898 Emergency steering valve .................................................................................................................................................................1899 Steering cylinder ........................................................................................................................................................................1900 Brake system .................................................................................................................................................................................1902 Brake accumulator charge valve ...........................................................................................................................................................1902 Slack adjuster ...........................................................................................................................................................................1903 Brake ....................................................................................................................................................................................1904 Parking brake ............................................................................................................................................................................1906 Parking brake solenoid valve .............................................................................................................................................................1907 Undercarriage and frame ......................................................................................................................................................................1908 Axle mount ...............................................................................................................................................................................1908 Center hinge pin .........................................................................................................................................................................1910 Hydraulic system .............................................................................................................................................................................1913 Hydraulic tank ...........................................................................................................................................................................1913 Double type gear pump ....................................................................................................................................................................1914 Steering and work equipment pump .........................................................................................................................................................1915 Control valve ............................................................................................................................................................................1919 Self-pressure reducing valve .............................................................................................................................................................1932 Work equipment PPC valve .................................................................................................................................................................1934 Work equipment lock solenoid valve .......................................................................................................................................................1936 Work equipment ...............................................................................................................................................................................1937 Work equipment linkage ...................................................................................................................................................................1937 Bucket ...................................................................................................................................................................................1941 Work equipment cylinder ..................................................................................................................................................................1943 Cab and its attachments ......................................................................................................................................................................1944 Cab mount ................................................................................................................................................................................1944 Electrical system ............................................................................................................................................................................1945 Bucket positioner ........................................................................................................................................................................1945 Fork positioner ..........................................................................................................................................................................1946 Remote boom positioner ...................................................................................................................................................................1947 80 Appendix ......................................................................................................................................................................................1949 Table of contents ............................................................................................................................................................................1950 Air conditioner components ...................................................................................................................................................................1951 Precautions for refrigerant ..............................................................................................................................................................1951 Air conditioner component ................................................................................................................................................................1952 Configuration and function of refrigeration cycle ........................................................................................................................................1954 Outline of refrigeration cycle ...........................................................................................................................................................1955 Air conditioner unit .....................................................................................................................................................................1957 Dual pressure switch .....................................................................................................................................................................1962 Air conditioner controller ...............................................................................................................................................................1963 Compressor ...............................................................................................................................................................................1964 Condenser ................................................................................................................................................................................1965 Receiver drier ...........................................................................................................................................................................1966 Sunlight sensor ..........................................................................................................................................................................1968 Outer temperature sensor (outside air temperature sensor) ................................................................................................................................1969 Procedure for testing and troubleshooting ................................................................................................................................................1970 Circuit diagram and arrangement of connector pins ........................................................................................................................................1972 System diagram ...........................................................................................................................................................................1975 Parts and connectors layout ..............................................................................................................................................................1978 Testing with self-diagnosis function .....................................................................................................................................................1983 How to open the electrical system abnormality record screen in service mode of the machine monitor .......................................................................................1984 Testing temperature control system .......................................................................................................................................................1986 Testing vent (mode) changeover ...........................................................................................................................................................1988 Testing FRESH/RECIRC air changeover ......................................................................................................................................................1990 Testing evaporator temperature sensor ....................................................................................................................................................1992 Testing relays ...........................................................................................................................................................................1994 Troubleshooting chart 1 ..................................................................................................................................................................1996 Troubleshooting chart 2 ..................................................................................................................................................................1997 Information in troubleshooting table .....................................................................................................................................................1999 Failure code list related to air conditioner .............................................................................................................................................2000 Failure code [879AKA] A/C Inner Sensor Open Circuit ......................................................................................................................................2001 Failure code [879AKB] A/C Inner Sensor Short Circuit .....................................................................................................................................2003 Failure code [879BKA] A/C Outer Sensor Open Circuit ......................................................................................................................................2005 Failure code [879BKB] A/C Outer Sensor Short Circuit .....................................................................................................................................2007 Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................................................................................................2009 Failure code [879CKB] Ventilating Sensor Short Circuit ...................................................................................................................................2011 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..............................................................................................................................2013 Failure code [879EMC] Ventilation Damper Abnormality .....................................................................................................................................2015 Failure code [879FMC] Air Mix Damper Abnormality .........................................................................................................................................2018 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) .....................................................................................2021 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................................................................................................2024 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...................................................................................................2027 A-4 Troubleshooting for FRESH/RECIRC air changeover ......................................................................................................................................2030 Troubleshooting with gauge pressure ......................................................................................................................................................2032 Connection of service tool ...............................................................................................................................................................2035 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ..................................................................................................2037 Handling of compressor oil ...............................................................................................................................................................2039 90 Diagrams and drawings .........................................................................................................................................................................2041 Table of contents ............................................................................................................................................................................2042 Hydraulic circuit diagram ....................................................................................................................................................................2043 Symbols in hydraulic circuit diagram .....................................................................................................................................................2043 Hydraulic circuit diagram ................................................................................................................................................................2047 Electric circuit diagram .....................................................................................................................................................................2049 Symbols in electric circuit diagram ......................................................................................................................................................2049 Electrical circuit diagram of machine body ...............................................................................................................................................2053 Electrical circuit diagram of floor ......................................................................................................................................................2063 INDEX.............................................................................................................................................................................................2079
DESCRIPTION:
KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL SEN06202-12 – PDF DOWNLOAD
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 27/12/24
