Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL SEN06255-10 – PDF DOWNLOAD
$42.95
KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL SEN06255-10 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL SEN06255-10 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL SEN06255-10 – PDF DOWNLOAD
Language : English
Pages : 2088
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL SEN06255-10 – 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 .................................................................................................................................................................................. 133 Power train system ....................................................................................................................................................................... 133 Layout of power train parts .............................................................................................................................................................. 135 Damper ................................................................................................................................................................................... 136 HST pump ................................................................................................................................................................................. 137 HST motor1 ............................................................................................................................................................................... 150 HST motor2 ............................................................................................................................................................................... 152 Transfer ................................................................................................................................................................................. 157 Clutch solenoid valve .................................................................................................................................................................... 164 Drive shaft .............................................................................................................................................................................. 166 Axle ..................................................................................................................................................................................... 167 Differential ............................................................................................................................................................................. 169 Torque proportional differential ......................................................................................................................................................... 173 Limited slip differential ................................................................................................................................................................ 175 Final drive .............................................................................................................................................................................. 180 Steering system .............................................................................................................................................................................. 183 Layout of steering devices ............................................................................................................................................................... 183 Steering column .......................................................................................................................................................................... 184 Priority valve ........................................................................................................................................................................... 185 Cushion valve ............................................................................................................................................................................ 189 Emergency steering valve ................................................................................................................................................................. 190 Orbitrol valve ........................................................................................................................................................................... 193 2way restrictor valve .................................................................................................................................................................... 199 Brake system ................................................................................................................................................................................. 200 Layout of brake parts .................................................................................................................................................................... 200 Brake accumulator charge valve ........................................................................................................................................................... 202 Brake valve .............................................................................................................................................................................. 207 Brake accumulator ........................................................................................................................................................................ 211 Slack adjuster ........................................................................................................................................................................... 212 Brake .................................................................................................................................................................................... 214 Parking brake control .................................................................................................................................................................... 217 Parking brake ............................................................................................................................................................................ 218 Parking brake solenoid valve ............................................................................................................................................................. 219 Undercarriage and frame ...................................................................................................................................................................... 221 Axle mount ............................................................................................................................................................................... 221 Center hinge pin ......................................................................................................................................................................... 223 Tire ..................................................................................................................................................................................... 224 Hydraulic system ............................................................................................................................................................................. 226 Hydraulic component layout ............................................................................................................................................................... 226 Work equipment control ................................................................................................................................................................... 228 Hydraulic tank ........................................................................................................................................................................... 229 Double type gear pump .................................................................................................................................................................... 232 Steering and work equipment pump ......................................................................................................................................................... 233 Control valve ............................................................................................................................................................................ 245 CLSS ..................................................................................................................................................................................... 255 Hydraulic circuit diagram and names of valves ............................................................................................................................................ 259 Self-pressure reducing valve ............................................................................................................................................................. 272 Work equipment PPC valve ................................................................................................................................................................. 277 Work equipment lock solenoid valve ....................................................................................................................................................... 285 PPC circuit accumulator .................................................................................................................................................................. 286 ECSS accumulator ......................................................................................................................................................................... 287 Work equipment ............................................................................................................................................................................... 288 Work equipment linkage ................................................................................................................................................................... 288 Bucket ................................................................................................................................................................................... 289 Cab and its attachments ...................................................................................................................................................................... 290 ROPS cab ................................................................................................................................................................................. 290 Cab mount ................................................................................................................................................................................ 292 Electrical system ............................................................................................................................................................................ 293 Engine control system .................................................................................................................................................................... 293 Preheating system ........................................................................................................................................................................ 296 Engine output limit function ............................................................................................................................................................. 298 Automatic warm-up function ............................................................................................................................................................... 299 Parking brake control system ............................................................................................................................................................. 300 System operating lamp function ........................................................................................................................................................... 304 Battery disconnect switch function ....................................................................................................................................................... 305 HST controller system .................................................................................................................................................................... 307 Machine monitor system ................................................................................................................................................................... 347 Rearview monitor system .................................................................................................................................................................. 368 KOMTRAX system ........................................................................................................................................................................... 371 System component parts ................................................................................................................................................................... 374 Sensor ................................................................................................................................................................................... 397 20 Standard value tables ......................................................................................................................................................................... 417 Table of contents ............................................................................................................................................................................ 418 Standard service value table ................................................................................................................................................................. 419 Standard value table for engine .......................................................................................................................................................... 419 Standard value table for machine ......................................................................................................................................................... 421 Standard value table for electrical system ............................................................................................................................................... 433 30 Testing and adjusting ......................................................................................................................................................................... 443 Table of contents ............................................................................................................................................................................ 444 Related information on testing and adjusting ................................................................................................................................................. 446 Tools for testing and adjusting .......................................................................................................................................................... 446 Sketch of tools for testing and adjusting ................................................................................................................................................ 452 Engine and cooling system .................................................................................................................................................................... 453 Testing engine speed ..................................................................................................................................................................... 453 Testing boost pressure ................................................................................................................................................................... 454 Testing exhaust gas temperature .......................................................................................................................................................... 456 Testing exhaust gas color ................................................................................................................................................................ 457 Testing mass air flow and temperature sensor.............................................................................................................................................. 459 Testing and adjusting valve clearance .................................................................................................................................................... 461 Testing compression pressure ............................................................................................................................................................. 463 Testing blowby pressure .................................................................................................................................................................. 467 Testing engine oil pressure .............................................................................................................................................................. 468 Testing EGR valve and KVGT oil pressures ................................................................................................................................................. 469 Testing fuel pressure .................................................................................................................................................................... 470 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 .......................................................................................................................................................... 622 Handling voltage circuit of engine controller ............................................................................................................................................ 623 Handling battery disconnect switch ....................................................................................................................................................... 624 Testing diodes ........................................................................................................................................................................... 625 Pm clinic .................................................................................................................................................................................... 626 Pm Clinic service ........................................................................................................................................................................ 626 Check sheet .............................................................................................................................................................................. 627 40 Troubleshooting ............................................................................................................................................................................... 631 Table of contents ............................................................................................................................................................................ 632 Related information on troubleshooting ....................................................................................................................................................... 641 Troubleshooting points ................................................................................................................................................................... 641 Sequence of events in troubleshooting .................................................................................................................................................... 643 Checks before troubleshooting ............................................................................................................................................................ 645 Inspection procedure before troubleshooting .............................................................................................................................................. 647 Preparation for troubleshooting of electrical system ..................................................................................................................................... 664 Classification and procedures for troubleshooting ........................................................................................................................................ 670 Symptom and troubleshooting numbers ...................................................................................................................................................... 673 Information described in troubleshooting table ........................................................................................................................................... 676 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit .................................................................................................. 678 Connector list and layout ................................................................................................................................................................ 681 Connector contact identification ......................................................................................................................................................... 695 T-branch box and T-branch adapter table .................................................................................................................................................. 734 Fuse location table ...................................................................................................................................................................... 739 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ............................................................................................................................ 742 Precautions when performing troubleshooting of machine monitor ........................................................................................................................... 745 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit .................................................................................................. 747 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .......................................................................................................... 752 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) .............................................................................................. 753 Failure codes table ...................................................................................................................................................................... 754 Troubleshooting by failure code (Display of code) ............................................................................................................................................ 766 Failure code [2F00MA] Failure of Parking Brake Circuit ................................................................................................................................... 766 Failure code [2F00MB] Malfunction of Parking Brake ....................................................................................................................................... 769 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................................................................................................... 771 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ................................................................................................................................ 773 Failure code [6091NX] HST Oil Filter Clogging ............................................................................................................................................ 775 Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ......................................................................................................................... 777 Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. .......................................................................................................................... 779 Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ............................................................................................................................. 781 Failure code [879AKA] A/C Inner Sensor Open Circuit ...................................................................................................................................... 783 Failure code [879AKB] A/C Inner Sensor Short Circuit ..................................................................................................................................... 784 Failure code [879BKA] A/C Outer Sensor Open Circuit ...................................................................................................................................... 785 Failure code [879BKB] A/C Outer Sensor Short Circuit ..................................................................................................................................... 786 Failure code [879CKA] Ventilating Sensor Open Circuit .................................................................................................................................... 787 Failure code [879CKB] Ventilating Sensor Short Circuit ................................................................................................................................... 788 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................................................................................................. 789 Failure code [879EMC] Ventilation Damper Abnormality ..................................................................................................................................... 790 Failure code [879FMC] Air Mix Damper Abnormality ......................................................................................................................................... 791 Failure code [989L00] Engine Controller Lock Caution 1 ................................................................................................................................... 792 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................................................................................... 793 Failure code [989N00] Engine Controller Lock Caution 3 ................................................................................................................................... 794 Failure code [A1U0N3] HC Desorb Request 1 ................................................................................................................................................ 795 Failure code [A1U0N4] HC Desorb Request 2 ................................................................................................................................................ 797 Failure code [AB00KE] Charge Voltage Low ................................................................................................................................................. 799 Failure code [AB00KY] Hot Short of Alternator R Terminal ................................................................................................................................. 800 Failure code [B@BAZG] Eng Oil Press Low .................................................................................................................................................. 801 Failure code [B@BCNS] Eng Water Overheat ................................................................................................................................................. 802 Failure code [B@BCZK] Eng Water Level Low ................................................................................................................................................ 803 Failure code [B@CRNS] HST Oil Temp. Overheat ............................................................................................................................................. 805 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................................................................................................... 806 Failure code [CA122] Chg Air Press Sensor High Error ..................................................................................................................................... 807 Failure code [CA123] Chg Air Press Sensor Low Error ...................................................................................................................................... 809 Failure code [CA131] Throttle Sensor High Error .......................................................................................................................................... 811 Failure code [CA132] Throttle Sensor Low Error ........................................................................................................................................... 813 Failure code [CA144] Coolant Temp Sens High Error ........................................................................................................................................ 815 Failure code [CA145] Coolant Temp Sens Low Error ......................................................................................................................................... 817 Failure code [CA153] Chg Air Temp Sensor High Error ...................................................................................................................................... 819 Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................................................................................................... 821 Failure code [CA187] Sensor 2 Supply Volt Low Error ...................................................................................................................................... 823 Failure code [CA221] Ambient Press Sensor High Error ..................................................................................................................................... 825 Failure code [CA222] Ambient Press Sensor Low Error ...................................................................................................................................... 827 Failure code [CA227] Sensor 2 Supply Volt High Error ..................................................................................................................................... 829 Failure code [CA234] Eng Overspeed ....................................................................................................................................................... 830 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................................................................................................... 831 Failure code [CA239] Ne Speed Sens Supply Volt High Error ................................................................................................................................ 832 Failure code [CA271] IMV/PCV1 Short Error ................................................................................................................................................ 833 Failure code [CA272] IMV/PCV1 Open Error ................................................................................................................................................. 835 Failure code [CA295] Ambient Press Sens In Range Error ................................................................................................................................... 837 Failure code [CA322] Inj #1(L#1) Open/Short Error ........................................................................................................................................ 838 Failure code [CA323] Inj #5(L#5) Open/Short Error ........................................................................................................................................ 840 Failure code [CA324] Inj #3(L#3) Open/Short Error ........................................................................................................................................ 842 Failure code [CA325] Inj #6(L#6) Open/Short Error ........................................................................................................................................ 844 Failure code [CA331] Inj #2(L#2) Open/Short Error ........................................................................................................................................ 846 Failure code [CA332] Inj #4(L#4) Open/Short Error ........................................................................................................................................ 848 Failure code [CA343] ECM Critical Internal Failure ....................................................................................................................................... 850 Failure code [CA351] Injectors Drive Circuit Error ....................................................................................................................................... 851 Failure code [CA352] Sensor 1 Supply Volt Low Error ...................................................................................................................................... 852 Failure code [CA356] Mass Air Flow Sensor High Error ..................................................................................................................................... 854 Failure code [CA357] Mass Air Flow Sensor Low Error ...................................................................................................................................... 856 Failure code [CA386] Sensor 1 Supply Volt High Error ..................................................................................................................................... 858 Failure code [CA428] Water in Fuel Sensor High Error ..................................................................................................................................... 859 Failure code [CA429] Water in Fuel Sensor Low Error ...................................................................................................................................... 861 Failure code [CA431] Idle Validation Sw Error ............................................................................................................................................ 863 Failure code [CA432] Idle Validation Process Error ....................................................................................................................................... 866 Failure code [CA435] Eng Oil Press Sw Error .............................................................................................................................................. 869 Failure code [CA441] Battery Voltage Low Error ........................................................................................................................................... 870 Failure code [CA442] Battery Voltage High Error .......................................................................................................................................... 872 Failure code [CA449] Rail Press Very High Error .......................................................................................................................................... 873 Failure code [CA451] Rail Press Sensor High Error ........................................................................................................................................ 874 Failure code [CA452] Rail Press Sensor Low Error ......................................................................................................................................... 876 Failure code [CA488] Chg Air Temp High Torque Derate ..................................................................................................................................... 878 Failure code [CA515] Rail Press Sens Sup Volt High Error ................................................................................................................................. 879 Failure code [CA516] Rail Press Sens Sup Volt Low Error .................................................................................................................................. 881 Failure code [CA553] Rail Press High Error ............................................................................................................................................... 883 Failure code [CA555] Crankcase Press High Error 1 ........................................................................................................................................ 884 Failure code [CA556] Crankcase Press High Error 2 ........................................................................................................................................ 885 Failure code [CA559] Rail Press Low Error ................................................................................................................................................ 886 Failure code [CA595] Turbo Speed High Error 2 ............................................................................................................................................ 888 Failure code [CA687] Turbo Speed Low Error ............................................................................................................................................... 889 Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................................................................................... 891 Failure code [CA691] Intake Air Temp Sens High Error ..................................................................................................................................... 893 Failure code [CA692] Intake Air Temp Sens Low Error ...................................................................................................................................... 895 Failure code [CA697] ECM Internal Temp Sensor High Error ................................................................................................................................. 897 Failure code [CA698] ECM Int Temp Sensor Low Error ....................................................................................................................................... 898 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..................................................................................................................................... 899 Failure code [CA778] Eng Bkup Speed Sensor Error ......................................................................................................................................... 901 Failure code [CA1117] Persistent Data Lost Error ......................................................................................................................................... 906 Failure code [CA1664] KDOC Malfunction ................................................................................................................................................... 907 Failure code [CA1691] Regeneration Ineffective ........................................................................................................................................... 910 Failure code [CA1695] Sensor 5 Supply Volt High Error .................................................................................................................................... 913 Failure code [CA1696] Sensor 5 Supply Volt Low Error ..................................................................................................................................... 914 Failure code [CA1843] Crankcase Press Sens High Error .................................................................................................................................... 916 Failure code [CA1844] Crankcase Press Sens Low Error ..................................................................................................................................... 918 Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................................................................................................... 920 Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................................................................................................... 922 Failure code [CA1883] KDPF Delta P Sens In Range Error ................................................................................................................................... 924 Failure code [CA1921] KDPF Soot Load High Error 1 ........................................................................................................................................ 928 Failure code [CA1922] KDPF Soot Load High Error 2 ........................................................................................................................................ 931 Failure code [CA1942] Crankcase Press Sens In Range Error ................................................................................................................................ 936 Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................................................................................................... 937 Failure code [CA2185] Throt Sensor Sup Volt High Error ................................................................................................................................... 940 Failure code [CA2186] Throt Sensor Sup Volt Low Error .................................................................................................................................... 942 Failure code [CA2249] Rail Press Very Low Error .......................................................................................................................................... 944 Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................................................................................................... 945 Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................................................................................................... 947 Failure code [CA2288] Turbo Speed High Error 1 ........................................................................................................................................... 950 Failure code [CA2311] IMV Solenoid Error ................................................................................................................................................. 951 Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................................................................................................... 952 Failure code [CA2353] EGR Valve Solenoid Short Error ..................................................................................................................................... 954 Failure code [CA2357] EGR Valve Servo Error .............................................................................................................................................. 956 Failure code [CA2373] Exhaust Manifold Press Sens High error ............................................................................................................................. 957 Failure code [CA2374] Exhaust Manifold Press Sens Low error .............................................................................................................................. 959 Failure code [CA2375] EGR Orifice Temp Sens High Error ................................................................................................................................... 961 Failure code [CA2376] EGR Orifice Temp Sens Low Error .................................................................................................................................... 963 Failure code [CA2381] KVGT Pos Sens High Error ........................................................................................................................................... 965 Failure code [CA2382] KVGT Pos Sens Low Error ............................................................................................................................................ 967 Failure code [CA2383] KVGT Solenoid Open Error ........................................................................................................................................... 970 Failure code [CA2386] KVGT Solenoid Short Error .......................................................................................................................................... 972 Failure code [CA2387] KVGT Servo Error ................................................................................................................................................... 974 Failure code [CA2554] Exh Manifold Press Sens In Range Error ............................................................................................................................. 979 Failure code [CA2555] Grid Htr Relay Volt Low Error ...................................................................................................................................... 982 Failure code [CA2556] Grid Htr Relay Volt High Error ..................................................................................................................................... 984 Failure code [CA2637] KDOC Face Plugging ................................................................................................................................................. 986 Failure code [CA2639] Manual Stationary Regeneration Request ............................................................................................................................. 988 Failure code [CA2961] EGR Orifice Temp High Error 1 ...................................................................................................................................... 991 Failure code [CA2973] Chg Air Press Sensor In Range Error ................................................................................................................................ 992 Failure code [CA3133] KDPF Outlet Press Sens High Error .................................................................................................................................. 993 Failure code [CA3134] KDPF Outlet Press Sens Low Error ................................................................................................................................... 995 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .............................................................................................................................. 997 Failure code [CA3251] KDOC Inlet Temp High Error .........................................................................................................................................1001 Failure code [CA3253] KDOC Temp Error - Non Regeneration .................................................................................................................................1004 Failure code [CA3254] KDOC Outlet Temp High Error 1 ......................................................................................................................................1008 Failure code [CA3255] KDPF Temp Error - Non Regeneration .................................................................................................................................1011 Failure code [CA3256] KDPF Outlet Temp High Error 1 ......................................................................................................................................1015 Failure code [CA3311] KDOC Outlet Temp High Error 2 ......................................................................................................................................1018 Failure code [CA3312] KDPF Outlet Temp High Error 2 ......................................................................................................................................1022 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...................................................................................................................................1026 Failure code [CA3314] KDOC Inlet Temp Sens High Error ....................................................................................................................................1029 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ................................................................................................................................1032 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....................................................................................................................................1036 Failure code [CA3317] KDOC Outlet Temp Sens High Error ...................................................................................................................................1039 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...............................................................................................................................1042 Failure code [CA3319] KDPF Outlet Temp Sens High Error ...................................................................................................................................1046 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....................................................................................................................................1049 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...............................................................................................................................1052 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...........................................................................................................................1056 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ............................................................................................................................1058 Failure code [CA3741] Rail Press Valve Trip Error ........................................................................................................................................1060 Failure code [D110L4] Disconnection of Battery Relay Signal ..............................................................................................................................1061 Failure code [D160KA] Disconnection of Backup Lamp Relay Output ..........................................................................................................................1063 Failure code [D160KY] Hot Short of Backup Lamp Relay Output ..............................................................................................................................1065 Failure code [D191KA] Disconnection of Neutral Output Relay ..............................................................................................................................1067 Failure code [D191KB] Ground Fault of Neutral Output Relay ...............................................................................................................................1069 Failure code [D191KY] Hot Short of Neutral Output Relay ..................................................................................................................................1071 Failure code [D192KA] Disconnection of ECSS Solenoid .....................................................................................................................................1073 Failure code [D192KB] Ground Fault of ECSS Solenoid ......................................................................................................................................1075 Failure code [D192KY] Hot Short of ECSS Solenoid .........................................................................................................................................1076 Failure code [D19JKZ] Personal Code Relay Abnormality ....................................................................................................................................1077 Failure code [D1B0KA] Disconnection of HST Safety Relay ..................................................................................................................................1079 Failure code [D1B0KB] Ground Fault of HST Safety Relay ...................................................................................................................................1081 Failure code [D1B0KY] Hot Short of HST Safety Relay ......................................................................................................................................1083 Failure code [D1B0MC] Malfunction of HST Safety Relay ....................................................................................................................................1085 Failure code [D1E6KA] Disconnection of Parking Brake Relay ...............................................................................................................................1086 Failure code [D1E6KB] Ground Fault of Parking Brake Relay ................................................................................................................................1088 Failure code [D1E6KY] Hot Short of Parking Brake Relay ...................................................................................................................................1090 Failure code [D5ZHKA] Failure of Key SW C Signal .........................................................................................................................................1092 Failure code [D5ZHKB] Key SW C Signal Short Circuit ......................................................................................................................................1094 Failure code [D5ZHL6] Disconnection of Key SW C ..........................................................................................................................................1096 Failure code [D811MC] KOMTRAX Error ......................................................................................................................................................1097 Failure code [D862KA] GPS Antenna Open Circuit ...........................................................................................................................................1098 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ..............................................................................................................................1099 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .............................................................................................................................1101 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ............................................................................................................................................1103 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..............................................................................................................................................1104 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...........................................................................................................................1106 Failure code [DAF0MB] Monitor ROM Abnormality ............................................................................................................................................1107 Failure code [DAF0MC] Monitor Error ......................................................................................................................................................1108 Failure code [DAF3KK] Controller Power Source Low (MON) ..................................................................................................................................1109 Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................................................................................................1111 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .............................................................................................................................1112 Failure code [DAFGMC] GPS Module Error ...................................................................................................................................................1113 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ..................................................................................................................................1114 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) .................................................................................................................................1116 Failure code [DAFQKR] CAN2 Discon (Monitor) ..............................................................................................................................................1118 Failure code [DAJ0KK] Controller Power Source Low (HST) ..................................................................................................................................1119 Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ...........................................................................................................................1122 Failure code [DAJ0MC] HST Con Error ......................................................................................................................................................1123 Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ..................................................................................................................................1124 Failure code [DAJ2KK] Solenoid Power Source Low (HST) ....................................................................................................................................1126 Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ............................................................................................................................1129 Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay .................................................................................................................................1131 Failure code [DAJ5KX] Failure of 5V Power Source 0 .......................................................................................................................................1133 Failure code [DAJ6KX] Failure of 5V Power Source 1 .......................................................................................................................................1135 Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) .............................................................................................................................1137 Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ..................................................................................................................................1138 Failure code [DAJLKB] Operating Lamp Short Circuit (HST) .................................................................................................................................1140 Failure code [DAJQKR] CAN2 Discon ( HST Con) .............................................................................................................................................1142 Failure code [DAJRKR] CAN1 Discon ( HST Con) .............................................................................................................................................1143 Failure code [DAJRMA] Inconsistency of Option Selection (HST) ............................................................................................................................1144 Failure code [DAZ9KQ] A/C Model Selection Abnormality ....................................................................................................................................1145 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...........................................................................................................................................1146 Failure code [DB2QKR] CAN2 Discon (Engine Con) ...........................................................................................................................................1147 Failure code [DB2RKR] CAN1 Discon (Engine Con) ...........................................................................................................................................1152 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...........................................................................................................................1156 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch .........................................................................................................................1158 Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ................................................................................................................................1160 Failure code [DDB6L4] Parking Brake Signal Malfunction ...................................................................................................................................1162 Failure code [DDD7KA] Failure of Variable Speed Control ..................................................................................................................................1165 Failure code [DDD7KY] Hot Short of Variable Speed Control ................................................................................................................................1167 Failure code [DDK3KA] FNR SW Input Signal Disconnection ..................................................................................................................................1169 Failure code [DDK3KB] FNR SW Input Signal Short Circuit ..................................................................................................................................1171 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...............................................................................................................................1173 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...............................................................................................................................1176 Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ............................................................................................................................1178 Failure code [DF10KA] Disconnection of Speed Range Input .................................................................................................................................1180 Failure code [DF10KB] Ground Fault of Speed Range Input ..................................................................................................................................1183 Failure code [DGH1KX] Out of Range of HST Oil Temp. Sensor ...............................................................................................................................1186 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor .............................................................................................................................1188 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ..................................................................................................................................1190 Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ...........................................................................................................................1192 Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) .........................................................................................................................1194 Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ...........................................................................................................................1196 Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) .........................................................................................................................1198 Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) .............................................................................................................................1200 Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ...........................................................................................................................1202 Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ...........................................................................................................................1204 Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. .........................................................................................................................1206 Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ............................................................................................................................1208 Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ..........................................................................................................................1210 Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ............................................................................................................................1212 Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ..........................................................................................................................1214 Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ...........................................................................................................................1216 Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit .........................................................................................................................1218 Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ...........................................................................................................................1220 Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit .........................................................................................................................1222 Failure code [DHT8ZG] Steering Oil Pressure Low ..........................................................................................................................................1224 Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ...........................................................................................................................1225 Failure code [DJF1KA] Disconnection of Fuel Level Sensor .................................................................................................................................1227 Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................................................................................................1229 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ............................................................................................................................1232 Failure code [DK55L5] Failure of FNR Lever Potentio ......................................................................................................................................1234 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...............................................................................................................................1235 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) .............................................................................................................................1238 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...........................................................................................................................1241 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ................................................................................................................................1244 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ..............................................................................................................................1247 Failure code [DK70KA] Failure of inching sensor Circuit ..................................................................................................................................1250 Failure code [DK70KY] Hot Short of inching sensor Circuit ................................................................................................................................1253 Failure code [DKA0KA] Failure of Boom Angle Sensor .......................................................................................................................................1255 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .............................................................................................................................1257 Failure code [DKA0L0] Boom Angle Sensor Dislocation ......................................................................................................................................1259 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor .........................................................................................................................1261 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...............................................................................................................................1263 Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ...........................................................................................................................1264 Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ...........................................................................................................................1266 Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ...............................................................................................................................1268 Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ..............................................................................................................................1271 Failure code [DPQ1KR] LIN Discon (Switch Panel) ..........................................................................................................................................1273 Failure code [DPQ2KR] LIN Discon (LED Unit) ..............................................................................................................................................1276 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) .....................................................................................................................................1279 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...........................................................................................................................................1282 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ............................................................................................................................1284 Failure code [DV00KB] Ground Fault of Buzzer Output ......................................................................................................................................1286 Failure code [DW26KA] Disconnection of Motor 2 Solenoid ..................................................................................................................................1288 Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ...................................................................................................................................1290 Failure code [DW26KY] Hot Short of Motor 2 Solenoid ......................................................................................................................................1292 Failure code [DW4BKA] Disconnection of Parking Brake Valve ...............................................................................................................................1294 Failure code [DW4BKB] Ground Fault of Parking Brake Valve ................................................................................................................................1296 Failure code [DW4BKY] Hot Short of Parking Brake Valve ...................................................................................................................................1298 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ............................................................................................................................1299 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .........................................................................................................................1301 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ............................................................................................................................1303 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid .............................................................................................................................1304 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ..............................................................................................................................1306 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid .................................................................................................................................1308 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ............................................................................................................................1309 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) .............................................................................................................................1311 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ................................................................................................................................1313 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..........................................................................................................................1315 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...........................................................................................................................1317 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ..............................................................................................................................1319 Failure code [DX19KA] Disconnection of Motor 1 Solenoid ..................................................................................................................................1320 Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ...................................................................................................................................1322 Failure code [DX19KY] Hot Short of Motor 1 Solenoid ......................................................................................................................................1324 Failure code [DX20KA] Disconnection of Clutch Control Solenoid ...........................................................................................................................1326 Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ............................................................................................................................1328 Failure code [DX20KY] Hot Short of Clutch Control Solenoid ...............................................................................................................................1330 Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. .................................................................................................................................1332 Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ..................................................................................................................................1334 Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. .....................................................................................................................................1336 Failure code [DXH7KA] Disconnection of Reverse Solenoid ..................................................................................................................................1338 Failure code [DXH7KB] Ground Fault of Reverse Solenoid ...................................................................................................................................1340 Failure code [DXH7KY] Hot Short of Reverse Solenoid ......................................................................................................................................1342 Failure code [DXH8KA] Disconnection of Forward Solenoid ..................................................................................................................................1344 Failure code [DXH8KB] Ground Fault of Forward Solenoid ...................................................................................................................................1346 Failure code [DXH8KY] Hot Short of Forward Solenoid ......................................................................................................................................1348 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ............................................................................................................................1350 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) .............................................................................................................................1352 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ................................................................................................................................1354 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ............................................................................................................................1355 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) .............................................................................................................................1357 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ................................................................................................................................1359 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...............................................................................................................................1360 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal .............................................................................................................................1363 Failure code [J141N1] Steering Pump Over Run .............................................................................................................................................1365 Failure code [LA00L3] Failure of Fan Reverse .............................................................................................................................................1366 Failure code [M100N1] HST Pump Over Run ..................................................................................................................................................1367 Failure code [M400N1] HST Motor 1 Over Run ...............................................................................................................................................1368 Troubleshooting of electrical system (E-mode) ................................................................................................................................................1369 E-1 Engine does not start ................................................................................................................................................................1369 E-2 Manual preheating system does not work ...............................................................................................................................................1376 E-3 Automatic preheating system does not work ............................................................................................................................................1379 E-4 While preheating is working, preheating monitor does not light up ....................................................................................................................1381 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .........................................................................................................1383 E-6 LCD unit on machine monitor displays nothing .........................................................................................................................................1386 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ................................................................................................1388 E-8 LCD on machine monitor does not display properly .....................................................................................................................................1390 E-9 Meter unit display on machine monitor is abnormal ....................................................................................................................................1392 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ....................................................................................................................1395 E-11 Caution LED on machine monitor is abnormal ..........................................................................................................................................1398 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ............................................................................................1400 E-13 Two switches operation of switch panel on machine monitor does not function .........................................................................................................1402 E-14 Switch panel buzzer of machine monitor is abnormal ..................................................................................................................................1405 E-15 Rearview monitor does not light up or backlight flickers ............................................................................................................................1407 E-16 Rearview monitor images are not displayed clearly ...................................................................................................................................1410 E-17 Rearview monitor brightness cannot be adjusted ......................................................................................................................................1413 E-18 Night lighting lamp of rearview monitor is abnormal .................................................................................................................................1416 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ................................................................................................1418 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ..................................................................................1419 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light .......................................................................................1423 E-22 The HST oil filter clogging caution lamp does not light up ..........................................................................................................................1425 E-23 Radiator coolant level caution lamp does not light ..................................................................................................................................1427 E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light .......................................................................1429 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 ....1430 E-26 Fuel level gauge does not indicate correct level ....................................................................................................................................1432 E-27 Seat belt caution lamp indication is abnormal .......................................................................................................................................1434 E-28 Horn does not sound .................................................................................................................................................................1435 E-29 Horn does not stop sounding .........................................................................................................................................................1438 E-30 Alarm buzzer does not sound .........................................................................................................................................................1440 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding .........................................................................................................1442 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 ................1443 E-33 Setting does not change while operating traction control switch .....................................................................................................................1445 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 .......................................................1447 E-35 Remote positioner does not work or cannot be released ...............................................................................................................................1450 E-36 Bucket positioner does not work or cannot be released ...............................................................................................................................1452 E-37 Direction selector (FNR) switch mode is not selected or not released ................................................................................................................1455 E-38 PZ auto tilt-in does not work .......................................................................................................................................................1457 E-39 Tracktion level does not display MAX when max traction switch is turned ON ..........................................................................................................1460 E-40 ECSS function cannot be selected or cannot be released ..............................................................................................................................1462 E-41 None of headlamp, clearance lamp, and tail lamp lights ..............................................................................................................................1464 E-42 Clearance lamp, tail lamp and license-plate lamp do not light up or go out ..........................................................................................................1466 E-43 Both High and Low beams of headlamp do not light up or go out .......................................................................................................................1470 E-44 Low beam of headlamp does not light up or go out ....................................................................................................................................1474 E-45 High beam of headlamp does not light up or go out ...................................................................................................................................1476 E-46 Front working lamp does not light up or go out ......................................................................................................................................1478 E-47 Rear working lamp does not light up or go out .......................................................................................................................................1482 E-48 All of turn signal lamps and hazard lamps do not flash or go out ....................................................................................................................1486 E-49 Turn signal lamps do not flash or go out ............................................................................................................................................1489 E-50 Hazard lamp does not flash or go out ................................................................................................................................................1492 E-51 Brake lamp does not light or stays lighted ..........................................................................................................................................1495 E-52 Backup lamp does not light up or does not go out ....................................................................................................................................1498 E-53 Backup buzzer does not sound or continues to sound ..................................................................................................................................1501 E-54 Front wiper does not operate ........................................................................................................................................................1503 E-55 Rear wiper does not operate .........................................................................................................................................................1506 E-56 Window washer does not operate ......................................................................................................................................................1508 E-57 KOMTRAX system does not operate normally ............................................................................................................................................1511 Troubleshooting of hydraulic and mechanical system (H-mode) ..................................................................................................................................1513 Information described in troubleshooting table (H-mode) ..................................................................................................................................1513 System chart of hydraulic and mechanical systems .........................................................................................................................................1514 Failure mode and cause table .............................................................................................................................................................1516 H-1 Machine does not travel forward or backward ..........................................................................................................................................1522 H-2 Machine does not travel forward (Machine travels backward normally) ..................................................................................................................1525 H-3 Machine does not travel backward (Machine travels forward normally) ..................................................................................................................1526 H-4 Machine does not travel forward or backward fast .....................................................................................................................................1527 H-5 Machine does not travel forward fast (Machine travel backward fast) ..................................................................................................................1531 H-6 Machine does not travel backward fast (Machine travel forward fast) ..................................................................................................................1532 H-7 Machine lacks power neither when traveling forward nor backward ......................................................................................................................1533 H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ....................................................................................1536 H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ...................................................................................1537 H-10 Engine stalls during travel or engine speed drops significantly .....................................................................................................................1538 H-11 Steering wheel is too heavy to turn .................................................................................................................................................1539 H-12 Steering wheel is heavy to turn .....................................................................................................................................................1541 H-13 Machine sways or large shocks are made while machine turns ..........................................................................................................................1542 H-14 Machine unintentionally turns when machine travels ..................................................................................................................................1543 H-15 Wheel brakes do not work or are weak ................................................................................................................................................1544 H-16 Wheel brakes are not released or drag ...............................................................................................................................................1545 H-17 Parking brake does not work or it is weak ...........................................................................................................................................1546 H-18 Parking brake is not released or drags. .............................................................................................................................................1547 H-19 Boom does not rise ..................................................................................................................................................................1548 H-20 Boom moves slow or boom lacks lifting force .........................................................................................................................................1550 H-21 Rising boom slows down at certain height ............................................................................................................................................1552 H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground). .....................................................................................................1553 H-23 Hydraulic drift of boom is large ....................................................................................................................................................1554 H-24 Boom moves up and down during operation .............................................................................................................................................1555 H-25 Bucket does not tilt back ...........................................................................................................................................................1556 H-26 Bucket moves slow or lacks tilt-back force ..........................................................................................................................................1558 H-27 Bucket decelerates during tilt-back operation .......................................................................................................................................1560 H-28 Bucket cylinder does not hold bucket on ground ......................................................................................................................................1561 H-29 Hydraulic drift of bucket is large ..................................................................................................................................................1562 H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) .....................................................................................................1563 H-31 Boom and bucket control levers do not move smoothly and are heavy to move ...........................................................................................................1564 H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ..............................................................................................1565 H-33 Large shocks are made when work equipment starts to move and stops ..................................................................................................................1566 H-34 When certain work equipment is relieved hydraulically, other work equipment moves ...................................................................................................1567 H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ..............................................................................................................1568 H-36 Fan speed is abnormal (too high or low, or fan does not rotate) .....................................................................................................................1569 H-37 Unusual noise is heard from around fan ..............................................................................................................................................1571 Troubleshooting of engine (S-mode) ...........................................................................................................................................................1572 Information described in troubleshooting table (S mode) ..................................................................................................................................1572 S-1 Engine does not crank when starting switch is turned to START position ...............................................................................................................1573 S-2 Engine cranks but no exhaust smoke comes out .........................................................................................................................................1574 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .......................................................................................1575 S-4 Engine startability is poor ..........................................................................................................................................................1576 S-5 Engine does not pick up smoothly .....................................................................................................................................................1578 S-6 Engine stops during operation ........................................................................................................................................................1580 S-7 Engine runs rough or is unstable .....................................................................................................................................................1582 S-8 Engine lacks power ...................................................................................................................................................................1583 S-9 KDPF gets clogged in a short time ....................................................................................................................................................1585 S-10 Engine oil consumption is excessive .................................................................................................................................................1587 S-11 Engine oil becomes contaminated early ...............................................................................................................................................1588 S-12 Fuel consumption is excessive .......................................................................................................................................................1589 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....................................................................................................................1590 S-14 Oil pressure drops ..................................................................................................................................................................1591 S-15 Fuel mixes into engine oil ..........................................................................................................................................................1592 S-16 Water mixes into engine oil (milky) .................................................................................................................................................1593 S-17 Coolant temperature rises too high (overheating) ....................................................................................................................................1594 S-18 Unusual noise is heard ..............................................................................................................................................................1595 S-19 Vibration is excessive ..............................................................................................................................................................1596 S-20 Air cannot be bled from fuel circuit ................................................................................................................................................1598 S-21 Active regeneration is executed frequently ..........................................................................................................................................1599 S-22 Active regeneration takes time ......................................................................................................................................................1600 S-23 White smoke is exhausted during active regeneration .................................................................................................................................1601 50 Disassembly and assembly ......................................................................................................................................................................1603 Table of contents ............................................................................................................................................................................1604 Related information on disassembly and assembly ..............................................................................................................................................1606 How to read this manual ..................................................................................................................................................................1606 Coating materials list ...................................................................................................................................................................1608 Special tools list .......................................................................................................................................................................1612 Sketches of special tools ................................................................................................................................................................1619 Engine and cooling system ....................................................................................................................................................................1635 Removal and installation of supply pump assembly .........................................................................................................................................1635 Removal and installation of injector assembly ............................................................................................................................................1639 Removal and installation of cylinder head assembly .......................................................................................................................................1648 Removal and installation of engine hood assembly .........................................................................................................................................1655 Removal and installation of grille assembly ..............................................................................................................................................1658 Removal and installation of radiator core assembly .......................................................................................................................................1660 Removal and installation of aftercooler ..................................................................................................................................................1663 Removal and installation of hydraulic oil cooler .........................................................................................................................................1665 Removal and installation of engine assembly ..............................................................................................................................................1666 Removal and installation of engine front oil seal ........................................................................................................................................1672 Removal and installation of engine rear oil seal .........................................................................................................................................1675 Removal and installation of cooling fan and fan motor assembly ...........................................................................................................................1678 Removal and installation of KDPF assembly ................................................................................................................................................1680 Disassembly and assembly of KDPF assembly ................................................................................................................................................1684 Removal and installation of KCCV assembly ................................................................................................................................................1693 Removal and installation of air cleaner assembly .........................................................................................................................................1694 Removal and installation of KVGT assembly ................................................................................................................................................1696 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ...............................................................................................................1700 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ..............................................................................................................1702 Removal and installation of alternator belt ..............................................................................................................................................1705 Removal and installation of fuel tank assembly ...........................................................................................................................................1707 Power train ..................................................................................................................................................................................1710 Removal and installation of transfer assembly ............................................................................................................................................1710 Disassembly and assembly of transfer assembly ............................................................................................................................................1715 Disassembly and assembly of parking brake assembly .......................................................................................................................................1747 Disassembly and assembly of differential assembly ........................................................................................................................................1755 Removal and installation of front axle assembly ..........................................................................................................................................1779 Removal and installation of rear axle assembly ...........................................................................................................................................1781 Disassembly and assembly of axle housing assembly ........................................................................................................................................1784 Undercarriage and frame ......................................................................................................................................................................1793 Removal and installation of center hinge pin .............................................................................................................................................1793 Removal and installation of counterweight assembly .......................................................................................................................................1802 Hydraulic system .............................................................................................................................................................................1804 Removal and installation of hydraulic tank assembly ......................................................................................................................................1804 Removal and installation of control valve assembly .......................................................................................................................................1807 Disassembly and assembly of control valve assembly .......................................................................................................................................1811 Removal and installation of hydraulic pump assembly ......................................................................................................................................1814 Removal and installation of HST motor1 assembly ..........................................................................................................................................1818 Removal and installation of HST motor2 assembly ..........................................................................................................................................1820 Disassembly and assembly of hydraulic cylinder assembly ..................................................................................................................................1822 Work equipment ...............................................................................................................................................................................1829 Removal and installation of work equipment assembly ......................................................................................................................................1829 Cab and its attachments ......................................................................................................................................................................1835 Removal and installation of operator's cab and floor frame assembly ......................................................................................................................1835 Removal and installation of operator's cab glass (adhered glass) .........................................................................................................................1840 Removal and installation of operator's seat assembly .....................................................................................................................................1848 Removal and installation of seat belt ....................................................................................................................................................1850 Electrical system ............................................................................................................................................................................1851 Removal and installation of machine monitor assembly .....................................................................................................................................1851 Removal and installation of engine controller assembly ...................................................................................................................................1853 Removal and installation of HST controller assembly ......................................................................................................................................1855 Removal and installation of air conditioner controller assembly ..........................................................................................................................1857 Removal and installation of monitor controller assembly ..................................................................................................................................1858 Removal and installation of mass air flow and temperature sensor .........................................................................................................................1860 Removal and installation of KOMTRAX terminal assembly ....................................................................................................................................1861 Air conditioner unit .........................................................................................................................................................................1862 Removal and installation of air conditioner compressor ...................................................................................................................................1862 Removal and installation of air conditioner condenser ....................................................................................................................................1864 Removal and installation of air conditioner unit assembly ................................................................................................................................1866 60 Maintenance standard ..........................................................................................................................................................................1871 Table of contents ............................................................................................................................................................................1872 Engine and cooling system ....................................................................................................................................................................1873 Engine related parts .....................................................................................................................................................................1873 Cooling fan motor ........................................................................................................................................................................1874 Power train ..................................................................................................................................................................................1876 Damper ...................................................................................................................................................................................1876 Transfer .................................................................................................................................................................................1877 Drive shaft ..............................................................................................................................................................................1884 Axle .....................................................................................................................................................................................1885 Differential .............................................................................................................................................................................1887 Limited slip differential ................................................................................................................................................................1891 Final drive ..............................................................................................................................................................................1893 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 .............................................................................................................................................................................1914 Hydraulic tank ...........................................................................................................................................................................1914 Double type gear pump ....................................................................................................................................................................1915 Steering and work equipment pump .........................................................................................................................................................1916 Control valve ............................................................................................................................................................................1920 Self-pressure reducing valve .............................................................................................................................................................1933 Work equipment PPC valve .................................................................................................................................................................1935 Work equipment lock solenoid valve .......................................................................................................................................................1937 Work equipment ...............................................................................................................................................................................1938 Work equipment linkage ...................................................................................................................................................................1938 Bucket ...................................................................................................................................................................................1942 Work equipment cylinder ..................................................................................................................................................................1944 Cab and its attachments ......................................................................................................................................................................1945 Cab mount ................................................................................................................................................................................1945 Electrical system ............................................................................................................................................................................1946 Bucket positioner ........................................................................................................................................................................1946 Fork positioner ..........................................................................................................................................................................1947 Remote boom positioner ...................................................................................................................................................................1948 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 ......................................................................................................................................................2061 INDEX.............................................................................................................................................................................................2077
DESCRIPTION:
KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL SEN06255-10 – 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
