Komatsu Wa270-7 Wheel Loader Service Repair Shop Manual (Sn A27001 And Up) – PDF DOWNLOAD

Description

Komatsu Wa270-7 Wheel Loader Service Repair Shop Manual (Sn A27001 And Up)

LANGUAGE:ENGLISH
PAGES:2048
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FILE TYPE:PDF

KOMATSU WA270-7 WHEEL LOADER SERVICE REPAIR SHOP MANUAL (SN A27001 AND UP) – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu Wa270-7 Wheel Loader Service Repair Shop Manual (Sn A27001 And Up)

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 two 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.

TABLE OF CONTENTS:

Komatsu Wa270-7 Wheel Loader Service Repair Shop Manual (Sn A27001 And Up)

00 Index and foreword 00-1
Index 00-2
Foreword, safety and general information 00-17
Important safety notice 00-17
How to read the shop manual 00-24
Explanation of terms for maintenance standard 00-26
Handling equipment of fuel system devices 00-28
Handling of intake system parts 00-29
Handling of hydraulic equipment 00-30
Method of disconnecting and connecting of push-pull type coupler 00-32
Handling of electrical equipment 00-35
How to read electric wire code 00-43
Precautions when performing operation 00-46
Practical use of KOMTRAX 00-51
Standard tightening torque table 00-52
List of abbreviation 00-58
Conversion table 00-63
01 Specification01-1
Table of contents 01-2
Specifications01-3
Specification drawing 01-3
Specifications 01-5
Weight table 01-10
Table of fuel, coolant, and lubricants 01-12
10 Structure and function 10-1
Table of contents 10-2
Engine and cooling system10-4
Engine related parts 10-4
KVGT10-6
EGR system piping drawing 10-13
EGR system circuit diagram 10-15
EGR valve 10-17
EGR cooler 10-19
KCCV layout drawing 10-20
KCCV ventilator 10-22
KDPF 10-24
Cooling system 10-28
Cooling fan motor 10-30
Power train 10-40
Power train system 10-40
Layout of power train parts 10-42
Damper 10-43
HST pump 10-44
HST motor1 10-57
HST motor2 10-59
Transfer 10-64
Clutch solenoid valve 10-71
Drive shaft 10-73
Axle 10-74
Differential 10-76
Torque proportional differential 10-80
Limited slip differential 10-82
Final drive 10-87
Steering system 10-90
Layout of steering devices 10-90
Steering column 10-91
Priority valve 10-92
Cushion valve 10-96
00-2 WA270-7
00 Index and foreword
Index
Emergency steering valve 10-97
Orbitrol valve 10-100
2way restrictor valve 10-106
Brake system 10-107
Layout of brake parts 10-107
Brake accumulator charge valve 10-109
Brake valve 10-114
Brake accumulator 10-118
Slack adjuster 10-119
Brake 10-121
Parking brake control 10-124
Parking brake 10-125
Parking brake solenoid valve 10-126
Undercarriage and frame 10-128
Axle mount 10-128
Center hinge pin 10-130
Tire 10-131
Hydraulic system 10-133
Hydraulic component layout 10-133
Work equipment control 10-135
Hydraulic tank 10-136
Double type gear pump 10-139
Steering and work equipment pump 10-140
Control valve 10-152
CLSS 10-162
Hydraulic circuit diagram and names of valves 10-166
Self-pressure reducing valve 10-179
Work equipment PPC valve 10-184
Work equipment lock solenoid valve 10-192
PPC circuit accumulator 10-193
ECSS accumulator 10-194
Work equipment 10-195
Work equipment linkage 10-195
Bucket 10-196
Cab and its attachments 10-197
ROPS cab 10-197
Cab mount 10-199
Electrical system 10-200
Engine control system 10-200
Preheating system 10-203
Engine output limit function 10-205
Automatic warm-up function 10-206
Parking brake control system 10-207
System operating lamp function 10-211
Battery disconnect switch function 10-212
HSTcontroller system 10-214
Machine monitor system 10-254
Rearview monitor system 10-275
KOMTRAX system 10-278
System component parts 10-281
Sensor 10-304
20 Standard value tables20-1
Table of contents 20-2
Standard service value table20-3
Standard value table for engine 20-3
Standard value table for machine 20-5
Standard value table for electrical system 20-17
30 Testing and adjusting 30-1
Table of contents 30-2
WA270-7 00-3
00 Index and foreword
Index
Related information on testing and adjusting 30-4
Tools for testing and adjusting 30-4
Sketch of tools for testing and adjusting 30-10
Engine and cooling system 30-11
Testing engine speed 30-11
Testing boost pressure 30-12
Testing exhaust gas temperature 30-14
Testing exhaust gas color 30-15
Testing and adjusting valve clearance 30-17
Testing compression pressure 30-19
Testing blowby pressure 30-23
Testing engine oil pressure 30-24
Testing EGR valve and KVGT driving oil pressure 30-25
Testing fuel pressure 30-26
Testing fuel discharge, return and leakage 30-30
Bleeding air from fuel system 30-35
Testing fuel circuit for leakage 30-37
Handling cylinder cutout mode operation 30-38
Handling no-injection cranking operation 30-39
Testing of KDPF and muffler stack for looseness and damage 30-40
Testing of installed condition of cylinder heads and manifolds 30-41
Testing engine piping for damage and looseness 30-42
Testing and adjusting air conditioner compressor belt tension 30-43
Replacing alternator belt 30-44
Power train 30-45
Testing oil leakage from axle final drive 30-45
Testing drive shaft for looseness, backlash, and damage 30-46
Testing accelerator pedal 30-47
Testing and adjusting HSToil pressure 30-48
Testing transfer clutch control pressure 30-51
Steering system 30-52
Testing directional lever 30-52
Testing steering wheel 30-53
Testing work equipment control lever 30-55
Testing and adjusting steering circuit oil pressure 30-57
Bleeding air from steering cylinder circuit 30-59
Brake system 30-60
Testing brake pedal 30-60
Testing braking performance 30-61
Testing and adjusting of accumulator charge pressure 30-62
Testing wheel brake oil pressure 30-64
Testing lowering of wheel brake pressure 30-65
Testing wear of wheel brake disc 30-67
Bleeding air from wheel brake circuit 30-68
Releasing remaining pressure in brake accumulator circuit 30-69
Testing parking brake performance 30-70
Testing wear of parking brake disc 30-71
Testing parking brake release pressure 30-72
Method of releasing parking brake manually 30-73
Hydraulic system 30-74
Testing cooling fan speed 30-74
Testing cooling fan pump circuit oil pressure 30-75
Bleeding air from hydraulic fan circuit 30-77
Testing and adjusting work equipment PPC oil pressure 30-78
Testing and adjusting work equipment oil pressure 30-80
Bleeding air from work equipment circuit 30-84
Releasing remaining pressure from work equipment circuit 30-85
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with
nitrogen gas 30-87
00-4 WA270-7
00 Index and foreword
Index
Work equipment 30-91
Testing and adjusting bucket positioner and bucket proximity switch 30-91
Testing and adjusting boom position detection lever 30-93
Electrical system 30-94
Adjusting replaced, reassembled or added sensor, controller, etc with machine
monitor 30-94
Special functions of machine monitor 30-95
Adjusting rearview camera angle 30-173
Handling voltage circuit of engine controller 30-174
Handling battery disconnect switch 30-175
Testing diodes 30-176
Pm clinic 30-177
Pm Clinic service 30-177
Check sheet 30-178
40 Troubleshooting40-1
Table of contents 40-2
Related information on troubleshooting 40-11
Troubleshooting points 40-11
Sequence of events in troubleshooting 40-13
Checks before troubleshooting 40-15
Inspection procedure before troubleshooting 40-17
Preparation for troubleshooting of electrical system 40-34
Classification and procedures for troubleshooting 40-40
Symptom and troubleshooting numbers 40-43
Information described in troubleshooting table 40-46
Procedure for troubleshooting wiring harness of pressure sensor system for open
circuit 40-48
Connector list and layout 40-51
Connector contact identification 40-65
T-branch box and T-branch adapter table 40-103
Fuse location table 40-108
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 40-111
Precautions when performing troubleshooting of machine monitor 40-114
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit 40-116
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors) 40-121
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) 40-122
Failure codes table 40-123
Troubleshooting by failure code (Display of code) 40-135
Failure code [2F00MA] Failure of Parking Brake Circuit 40-135
Failure code [2F00MB] Malfunction of Parking Brake 40-138
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 40-140
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 40-142
Failure code [6091NX] HST Oil Filter Clogging 40-144
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol 40-146
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol 40-148
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol 40-150
Failure code [879AKA] A/C Inner Sensor Open Circuit 40-152
Failure code [879AKB] A/C Inner Sensor Short Circuit 40-153
Failure code [879BKA] A/C Outer Sensor Open Circuit 40-154
Failure code [879BKB] A/C Outer Sensor Short Circuit 40-155
Failure code [879CKA] Ventilating Sensor Open Circuit 40-156
Failure code [879CKB] Ventilating Sensor Short Circuit 40-157
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 40-158
Failure code [879EMC] Ventilation Damper Abnormality 40-159
Failure code [879FMC] Air Mix Damper Abnormality 40-160
Failure code [989L00] Engine Controller Lock Caution 1 40-161
WA270-7 00-5
00 Index and foreword
Index
Failure code [989M00] Engine Controller Lock Caution 2 40-162
Failure code [989N00] Engine Controller Lock Caution 3 40-163
Failure code [A1U0N3] HC Desorb Request 1 40-164
Failure code [A1U0N4] HC Desorb Request 2 40-166
Failure code [B@BAZG] Eng Oil Press Low 40-168
Failure code [B@BCNS] Eng Water Overheat 40-169
Failure code [B@BCZK] Eng Water Level Low 40-170
Failure code [B@CRNS] HST Oil Temp Overheat 40-172
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 40-173
Failure code [CA122] Chg Air Press Sensor High Error 40-174
Failure code [CA123] Chg Air Press Sensor Low Error 40-176
Failure code [CA131] Throttle Sensor High Error 40-178
Failure code [CA132] Throttle Sensor Low Error 40-180
Failure code [CA144] Coolant Temp Sens High Error 40-182
Failure code [CA145] Coolant Temp Sens Low Error 40-184
Failure code [CA153] Chg Air Temp Sensor High Error 40-186
Failure code [CA154] Chg Air Temp Sensor Low Error 40-188
Failure code [CA187] Sensor 2 Supply Volt Low Error 40-190
Failure code [CA221] Ambient Press Sensor High Error 40-192
Failure code [CA222] Ambient Press Sensor Low Error 40-194
Failure code [CA227] Sensor 2 Supply Volt High Error 40-196
Failure code [CA234] Eng Overspeed 40-197
Failure code [CA238] Ne Speed Sensor Supply Volt Error 40-198
Failure code [CA239] Ne Speed Sens Supply Volt High Error 40-199
Failure code [CA271] IMV/PCV1 Short Error 40-200
Failure code [CA272] IMV/PCV1 Open Error 40-202
Failure code [CA295] Ambient Press Sens In Range Error 40-204
Failure code [CA322] Inj #1(L#1) Open/Short Error 40-205
Failure code [CA323] Inj #5(L#5) Open/Short Error 40-207
Failure code [CA324] Inj #3(L#3) Open/Short Error 40-209
Failure code [CA325] Inj #6(L#6) Open/Short Error 40-211
Failure code [CA331] Inj #2(L#2) Open/Short Error 40-213
Failure code [CA332] Inj #4(L#4) Open/Short Error 40-215
Failure code [CA343] ECM Critical Internal Failure 40-217
Failure code [CA351] Injectors Drive Circuit Error 40-218
Failure code [CA352] Sensor 1 Supply Volt Low Error 40-219
Failure code [CA356] Mass Air Flow Sensor High Error 40-221
Failure code [CA357] Mass Air Flow Sensor Low Error 40-223
Failure code [CA386] Sensor 1 Supply Volt High Error 40-225
Failure code [CA428] Water in Fuel Sensor High Error 40-226
Failure code [CA429] Water in Fuel Sensor Low Error 40-228
Failure code [CA431] Idle Validation Sw Error 40-230
Failure code [CA432] Idle Validation Process Error 40-233
Failure code [CA435] Eng Oil Press Sw Error 40-236
Failure code [CA441] Battery Voltage Low Error 40-237
Failure code [CA442] Battery Voltage High Error 40-239
Failure code [CA449] Rail Press Very High Error 40-240
Failure code [CA451] Rail Press Sensor High Error 40-241
Failure code [CA452] Rail Press Sensor Low Error 40-243
Failure code [CA488] Chg Air Temp High Torque Derate 40-245
Failure code [CA515] Rail Press Sens Sup Volt High Error 40-246
Failure code [CA516] Rail Press Sens Sup Volt Low Error 40-248
Failure code [CA553] Rail Press High Error 40-250
Failure code [CA555] Crankcase Press High Error 1 40-251
Failure code [CA556] Crankcase Press High Error 2 40-252
Failure code [CA559] Rail Press Low Error 40-253
Failure code [CA595] Turbo Speed High Error 2 40-255
Failure code [CA687] Turbo Speed Low Error 40-256
Failure code [CA689] Eng Ne Speed Sensor Error 40-258
00-6 WA270-7
00 Index and foreword
Index
Failure code [CA691] Intake Air Temp Sens High Error 40-260
Failure code [CA692] Intake Air Temp Sens Low Error 40-262
Failure code [CA697] ECM Internal Temp Sensor High Error 40-264
Failure code [CA698] ECM Int Temp Sensor Low Error 40-265
Failure code [CA731] Eng Bkup Speed Sens Phase Error 40-266
Failure code [CA778] Eng Bkup Speed Sensor Error 40-268
Failure code [CA1117] Persistent Data Lost Error 40-273
Failure code [CA1664] KDOC Malfunction 40-274
Failure code [CA1691] Regeneration Ineffective 40-277
Failure code [CA1695] Sensor 5 Supply Volt High Error 40-280
Failure code [CA1696] Sensor 5 Supply Volt Low Error 40-281
Failure code [CA1843] Crankcase Press Sens High Error 40-283
Failure code [CA1844] Crankcase Press Sens Low Error 40-285
Failure code [CA1879] KDPF Delta P Sensor High Error 40-287
Failure code [CA1881] KDPF Delta P Sensor Low Error 40-289
Failure code [CA1883] KDPF Delta P Sens In Range Error 40-291
Failure code [CA1921] KDPF Soot Load High Error 1 40-295
Failure code [CA1922] KDPF Soot Load High Error 2 40-298
Failure code [CA1942] Crankcase Press Sens In Range Error 40-303
Failure code [CA1993] KDPF Delta Pressure Low Error 40-304
Failure code [CA2185] Throt Sensor Sup Volt High Error 40-307
Failure code [CA2186] Throt Sensor Sup Volt Low Error 40-309
Failure code [CA2249] Rail Press Very Low Error 40-311
Failure code [CA2271] EGR Valve Pos Sens High Error 40-312
Failure code [CA2272] EGR Valve Pos Sens Low Error 40-314
Failure code [CA2288] Turbo Speed High Error 1 40-317
Failure code [CA2311] IMV Solenoid Error 40-318
Failure code [CA2349] EGR Valve Solenoid Open Error 40-319
Failure code [CA2353] EGR Valve Solenoid Short Error 40-321
Failure code [CA2357] EGR Valve Servo Error 40-323
Failure code [CA2373] Exhaust Manifold Press Sens High error 40-324
Failure code [CA2374] Exhaust Manifold Press Sens Low error 40-326
Failure code [CA2375] EGR Orifice Temp Sens High Error 40-328
Failure code [CA2376] EGR Orifice Temp Sens Low Error 40-330
Failure code [CA2381] KVGT Pos Sens High Error 40-332
Failure code [CA2382] KVGT Pos Sens Low Error 40-334
Failure code [CA2383] KVGT Solenoid Open Error 40-337
Failure code [CA2386] KVGT Solenoid Short Error 40-339
Failure code [CA2387] KVGT Servo Error 40-341
Failure code [CA2554] Exh Manifold Press Sens In Range Error 40-342
Failure code [CA2555] Grid Htr Relay Volt Low Error 40-343
Failure code [CA2556] Grid Htr Relay Volt High Error 40-345
Failure code [CA2637] KDOC Face Plugging 40-347
Failure code [CA2639] Manual Stationary Regeneration Request 40-349
Failure code [CA2961] EGR Orifice Temp High Error 1 40-352
Failure code [CA2973] Chg Air Press Sensor In Range Error 40-353
Failure code [CA3133] KDPF Outlet Press Sens High Error 40-354
Failure code [CA3134] KDPF Outlet Press Sens Low Error 40-356
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 40-358
Failure code [CA3251] KDOC Inlet Temp High Error 40-362
Failure code [CA3253] KDOC Temp Error – Non Regeneration 40-365
Failure code [CA3254] KDOC Outlet Temp High Error 1 40-368
Failure code [CA3255] KDPF Temp Error – Non Regeneration 40-371
Failure code [CA3256] KDPF Outlet Temp High Error 1 40-374
Failure code [CA3311] KDOC Outlet Temp High Error 2 40-377
Failure code [CA3312] KDPF Outlet Temp High Error 2 40-380
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 40-383
Failure code [CA3314] KDOC Inlet Temp Sens High Error 40-386
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 40-389
WA270-7 00-7
00 Index and foreword
Index
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 40-393
Failure code [CA3317] KDOC Outlet Temp Sens High Error 40-396
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 40-399
Failure code [CA3319] KDPF Outlet Temp Sens High Error 40-403
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 40-406
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 40-409
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 40-413
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 40-415
Failure code [CA3741] Rail Press Valve Trip Error 40-417
Failure code [D110L4] Disconnection of Battery Relay Signal 40-418
Failure code [D160KA] Disconnection of Backup Lamp Relay Output 40-420
Failure code [D160KY] Hot Short of Backup Lamp Relay Output 40-422
Failure code [D191KA] Disconnection of Neutral Output Relay 40-424
Failure code [D191KB] Ground Fault of Neutral Output Relay 40-426
Failure code [D191KY] Hot Short of Neutral Output Relay 40-428
Failure code [D192KA] Disconnection of ECSS Solenoid 40-430
Failure code [D192KB] Ground Fault of ECSS Solenoid 40-432
Failure code [D192KY] Hot Short of ECSS Solenoid 40-433
Failure code [D19JKZ] Personal Code Relay Abnormality 40-434
Failure code [D1B0KA] Disconnection of HST Safety Relay 40-436
Failure code [D1B0KB] Ground Fault of HST Safety Relay 40-438
Failure code [D1B0KY] Hot Short of HST Safety Relay 40-440
Failure code [D1B0MC] Malfunction of HST Safety Relay 40-442
Failure code [D1E6KA] Disconnection of Parking Brake Relay 40-443
Failure code [D1E6KB] Ground Fault of Parking Brake Relay 40-445
Failure code [D1E6KY] Hot Short of Parking Brake Relay 40-447
Failure code [D5ZHKA] Failure of Key SW C Signal 40-449
Failure code [D5ZHKB] Key SW C Signal Short Circuit 40-451
Failure code [D5ZHL6] Disconnection of Key SW C 40-453
Failure code [D811MC] KOMTRAX Error 40-454
Failure code [D862KA] GPS Antenna Open Circuit 40-455
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 40-456
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 40-458
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 40-460
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 40-461
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 40-463
Failure code [DAF0MB] Monitor ROM Abnormality 40-464
Failure code [DAF0MC] Monitor Error 40-465
Failure code [DAF3KK] Controller Power Source Low (MON) 40-466
Failure code [DAF8KB] Camera Power Supply Short Circuit 40-468
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 40-469
Failure code [DAFGMC] GPS Module Error 40-470
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) 40-471
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 40-473
Failure code [DAFQKR] CAN2 Discon (Monitor) 40-475
Failure code [DAJ0KK] Controller Power Source Low (HST) 40-476
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) 40-479
Failure code [DAJ0MC] HST Con Error 40-480
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) 40-481
Failure code [DAJ2KK] Solenoid Power Source Low (HST) 40-483
Failure code [DAJ4KB] Ground Fault of Sol Self-Holding Relay 40-486
Failure code [DAJ4KZ] Failure of Sol Self-Holding Relay 40-488
Failure code [DAJ5KX] Failure of 5V Power Source 0 40-490
Failure code [DAJ6KX] Failure of 5V Power Source 1 40-492
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) 40-494
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) 40-495
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) 40-497
Failure code [DAJQKR] CAN2 Discon ( HST Con) 40-499
Failure code [DAJRKR] CAN1 Discon ( HST Con) 40-500
00-8 WA270-7
00 Index and foreword
Index
Failure code [DAJRMA] Inconsistency of Option Selection (HST) 40-501
Failure code [DAZ9KQ] A/C Model Selection Abnormality 40-502
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 40-503
Failure code [DB2QKR] CAN2 Discon (Engine Con) 40-504
Failure code [DB2RKR] CAN1 Discon (Engine Con) 40-509
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW 40-513
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 40-515
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction 40-517
Failure code [DDB6L4] Parking Brake Signal Malfunction 40-519
Failure code [DDD7KA] Failure of Variable Speed Control 40-522
Failure code [DDD7KY] Hot Short of Variable Speed Control 40-524
Failure code [DDK3KA] FNR SW Input Signal Disconnection 40-526
Failure code [DDK3KB] FNR SW Input Signal Short Circuit 40-528
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 40-530
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit 40-533
Failure code [DDNRLD] Ground Fault of Work Equip Lock Switch 40-535
Failure code [DF10KA] Disconnection of Speed Range Input 40-537
Failure code [DF10KB] Ground Fault of Speed Range Input 40-540
Failure code [DGR2KB] Ground Fault of Brake Oil Temp Sensor 40-543
Failure code [DGR2KZ] Failure of Brake Oil Temp Sensor 40-545
Failure code [DHG1KX] Out of Range of HST Oil Temp Sensor 40-547
Failure code [DHHBKA] Failure of HST Press Sens Circuit (MA) 40-549
Failure code [DHHBKY] Hot Short of HST Press Sens Circuit (MA) 40-551
Failure code [DHHCKA] Failure of HST Press Sens Circuit (MB) 40-553
Failure code [DHHCKY] Hot Short of HST Press Sens Circuit (MB) 40-555
Failure code [DHPCKA] Failure of Boom Press Sensor (Bottom) 40-557
Failure code [DHPCKY] Hot Short of Boom Press Sensor (Bottom) 40-559
Failure code [DHPEKA] Failure of Steering & Loader Pump Press 40-561
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press 40-563
Failure code [DHS8KA] Failure of Boom Raise PPC Sens Circuit 40-565
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens Circuit 40-567
Failure code [DHS9KA] Failure of Boom Lower PPC Sens Circuit 40-569
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens Circuit 40-571
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens Circuit 40-573
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens Circuit 40-575
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens Circuit 40-577
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens Circuit 40-579
Failure code [DHT8ZG] Steering Oil Pressure Low 40-581
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit 40-582
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 40-584
Failure code [DK55KA] Failure of FNR Lever Potentio 40-586
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit 40-589
Failure code [DK55L5] Failure of FNR Lever Potentio 40-591
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) 40-592
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) 40-595
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree 40-598
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) 40-601
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) 40-604
Failure code [DK70KA] Failure of inching sensor Circuit 40-607
Failure code [DK70KY] Hot Short of inching sensor Circuit 40-610
Failure code [DKA0KA] Failure of Boom Angle Sensor 40-612
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit 40-614
Failure code [DKA0L0] Boom Angle Sensor Dislocation 40-616
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 40-618
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 40-620
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) 40-622
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) 40-624
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) 40-626
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) 40-629
WA270-7 00-9
00 Index and foreword
Index
Failure code [DPQ1KR] LIN Discon (Switch Panel) 40-631
Failure code [DPQ2KR] LIN Discon (LED Unit) 40-634
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 40-637
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 40-640
Failure code [DT22KB] Ground Fault of Work Equip Lock Indic 40-642
Failure code [DV00KB] Ground Fault of Buzzer Output 40-644
Failure code [DW26KA] Disconnection of Motor 2 Solenoid 40-646
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid 40-648
Failure code [DW26KY] Hot Short of Motor 2 Solenoid 40-650
Failure code [DW4BKA] Disconnection of Parking Brake Valve 40-652
Failure code [DW4BKB] Ground Fault of Parking Brake Valve 40-654
Failure code [DW4BKY] Hot Short of Parking Brake Valve 40-656
Failure code [DW4RKA] Disconnection of Bucket EPC Sol (Tilt) 40-657
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) 40-659
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) 40-661
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid 40-662
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid 40-664
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid 40-666
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) 40-667
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) 40-669
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) 40-671
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) 40-673
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) 40-675
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) 40-677
Failure code [DX19KA] Disconnection of Motor 1 Solenoid 40-678
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid 40-680
Failure code [DX19KY] Hot Short of Motor 1 Solenoid 40-682
Failure code [DX20KA] Disconnection of Clutch Control Solenoid 40-684
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid 40-686
Failure code [DX20KY] Hot Short of Clutch Control Solenoid 40-688
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol 40-690
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol 40-692
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol 40-694
Failure code [DXH7KA] Disconnection of Reverse Solenoid 40-696
Failure code [DXH7KB] Ground Fault of Reverse Solenoid 40-698
Failure code [DXH7KY] Hot Short of Reverse Solenoid 40-700
Failure code [DXH8KA] Disconnection of Forward Solenoid 40-702
Failure code [DXH8KB] Ground Fault of Forward Solenoid 40-704
Failure code [DXH8KY] Hot Short of Forward Solenoid 40-706
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) 40-708
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 40-710
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) 40-712
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) 40-713
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 40-715
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) 40-717
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal 40-718
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal 40-721
Failure code [J141N1] Steering Pump Over Run 40-723
Failure code [LA00L3] Failure of Fan Reverse 40-724
Failure code [M100N1] HST Pump Over Run 40-725
Failure code [M400N1] HST Motor 1 Over Run 40-726
Troubleshooting of electrical system (E-mode) 40-727
E-1 Engine does not start 40-727
E-2 Manual preheating system does not work 40-734
E-3 Automatic preheating system does not work 40-737
E-4 While preheating is working, preheating monitor does not light up 40-739
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing 40-741
E-6 LCD unit on machine monitor displays nothing 40-744
00-10 WA270-7
00 Index and foreword
Index
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) 40-746
E-8 LCD on machine monitor does not display properly 40-748
E-9 Meter unit display on machine monitor is abnormal 40-750
E-10 Night lighting lamp of meter unit on machine monitor is abnormal 40-753
E-11 Caution LED on machine monitor is abnormal 40-756
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate
properly 40-758
E-13 Two switches operation of switch panel on machine monitor does not function 40-760
E-14 Switch panel buzzer of machine monitor is abnormal 40-763
E-15 Rearview monitor does not light up or backlight flickers 40-765
E-16 Rearview monitor images are not displayed clearly 40-768
E-17 Rearview monitor brightness cannot be adjusted 40-771
E-18 Night lighting lamp of rearview monitor is abnormal 40-774
E-19 Some items of gauges and caution lamps on machine monitor are not displayed
properly 40-776
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position 40-777
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
light 40-781
E-22 The HSToil filter clogging caution lamp does not light up 40-783
E-23 Radiator coolant level caution lamp does not light 40-785
E-24 Indication of HSToil temperature gauge does not increase, or HSToil temperature
caution lamp does not light 40-787
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 40-788
E-26 Fuel level gauge does not indicate correct level 40-790
E-27 Seat belt caution lamp indication is abnormal 40-792
E-28 Horn does not sound 40-793
E-29 Horn does not stop sounding 40-796
E-30 Alarm buzzer does not sound 40-798
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding 40-800
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 40-801
E-33 Setting does not change while operating traction control switch 40-803
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 40-805
E-35 Remote positioner does not work or cannot be released 40-808
E-36 Bucket positioner does not work or cannot be released 40-810
E-37 Direction selector (FNR) switch mode is not selected or not released 40-813
E-38 PZ auto tilt-in does not work 40-815
E-39 Tracktion level does not display MAX when max traction switch is turned ON 40-818
E-40 ECSS function cannot be selected or cannot be released 40-820
E-41 None of headlamp, clearance lamp, and tail lamp lights 40-822
E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out 40-824
E-43 Both High and Low beams of headlamp do not light up or go out 40-828
E-44 Low beam of headlamp does not light up or go out 40-832
E-45 High beam of headlamp does not light up or go out 40-834
E-46 Front working lamp does not light up or go out 40-836
E-47 Rear working lamp does not light up or go out 40-840
E-48 All of turn signal lamps and hazard lamps do not flash or go out 40-844
E-49 Turn signal lamps do not flash or go out 40-847
E-50 Hazard lamp does not flash or go out 40-850
E-51 Brake lamp does not light or stays lighted 40-853
E-52 Backup lamp does not light up or does not go out 40-856
E-53 Backup buzzer does not sound or continues to sound 40-859
E-54 Front wiper does not operate 40-861
WA270-7 00-11
00 Index and foreword
Index
E-55 Rear wiper does not operate 40-864
E-56 Window washer does not operate 40-866
E-57 KOMTRAX system does not operate normally 40-869
Troubleshooting of hydraulic and mechanical system (H-mode) 40-871
Information described in troubleshooting table (H-mode) 40-871
System chart of hydraulic and mechanical systems 40-872
Failure mode and cause table 40-874
H-1 Machine does not travel forward or backward 40-881
H-2 Machine does not travel forward (Machine travels backward normally) 40-884
H-3 Machine does not travel backward (Machine travels forward normally) 40-885
H-4 Machine does not travel forward or backward fast 40-886
H-5 Machine does not travel forward fast (Machine travel backward fast) 40-890
H-6 Machine does not travel backward fast (Machine travel forward fast) 40-891
H-7 Machine lacks power neither when traveling forward nor backward 40-892
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling
backward) 40-895
H-9 Machine lacks power when traveling backward (Machine have sufficient power when
traveling forward) 40-896
H-10 Engine stalls during travel or engine speed drops significantly 40-897
H-11 Steering wheel is too heavy to turn 40-898
H-12 Steering wheel is heavy to turn 40-900
H-13 Machine sways or large shocks are made while machine turns 40-901
H-14 Machine unintentionally turns when machine travels 40-902
H-15 Wheel brakes do not work or are weak 40-903
H-16 Wheel brakes are not released or drag 40-904
H-17 Parking brake does not work or it is weak 40-905
H-18 Parking brake is not released or drags 40-906
H-19 Boom does not rise 40-907
H-20 Boom moves slow or boom lacks lifting force 40-909
H-21 Rising boom slows down at certain height 40-911
H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground) 40-912
H-23 Hydraulic drift of boom is large 40-913
H-24 Boom moves up and down during operation 40-914
H-25 Bucket does not tilt back 40-915
H-26 Bucket moves slow or lacks tilt-back force 40-917
H-27 Bucket decelerates during tilt-back operation 40-919
H-28 Bucket cylinder does not hold bucket on ground 40-920
H-29 Hydraulic drift of bucket is large 40-921
H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) 40-922
H-31 Boom and bucket control levers do not move smoothly and are heavy to move 40-923
H-32 Operating work equipment causes engine speed to lower significantly or engine to
stall 40-924
H-33 Large shocks are made when work equipment starts to move and stops 40-925
H-34 When certain work equipment is relieved hydraulically, other work equipment
moves 40-926
H-35 ECSS (travel damper) does not work and machine pitches and bounces 40-927
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) 40-928
H-37 Unusual noise is heard from around fan 40-930
Troubleshooting of engine (S-mode) 40-931
Information described in troubleshooting table (S mode) 40-931
S-1 Engine does not crank when starting switch is turned to START position 40-932
S-2 Engine cranks but no exhaust smoke comes out 40-933
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start) 40-934
S-4 Engine startability is poor 40-935
S-5 Engine does not pick up smoothly 40-937
S-6 Engine stops during operation 40-939
S-7 Engine runs rough or is unstable 40-941
S-8 Engine lacks power 40-942
00-12 WA270-7
00 Index and foreword
Index
S-9 KDPF gets clogged in a short time 40-944
S-10 Engine oil consumption is excessive 40-946
S-11 Engine oil becomes contaminated early 40-947
S-12 Fuel consumption is excessive 40-948
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 40-949
S-14 Oil pressure drops 40-950
S-15 Fuel mixes into engine oil 40-951
S-16 Water mixes into engine oil (milky) 40-952
S-17 Coolant temperature rises too high (overheating) 40-953
S-18 Unusual noise is heard 40-954
S-19 Vibration is excessive 40-955
S-20 Air cannot be bled from fuel circuit 40-957
S-21 Active regeneration is executed frequently 40-958
S-22 Active regeneration takes time 40-959
S-23 White smoke is exhausted during active regeneration 40-960
50 Disassembly and assembly 50-1
Table of contents 50-2
Related information on disassembly and assembly50-4
How to read this manual 50-4
Coating materials list 50-6
Special tools list 50-10
Sketches of special tools 50-17
Engine and cooling system 50-33
Removal and installation of supply pump assembly 50-33
Removal and installation of injector assembly 50-37
Removal and installation of cylinder head assembly 50-46
Removal and installation of engine hood assembly 50-53
Removal and installation of grille assembly 50-56
Removal and installation of radiator core assembly 50-58
Removal and installation of aftercooler 50-61
Removal and installation of hydraulic oil cooler 50-63
Removal and installation of engine assembly 50-64
Removal and installation of engine front oil seal 50-70
Removal and installation of engine rear oil seal 50-73
Removal and installation of cooling fan and fan motor assembly 50-76
Removal and installation of KDPF assembly 50-78
Disassembly and assembly of KDPF assembly 50-82
Removal and installation of KCCV assembly 50-91
Removal and installation of air cleaner assembly 50-92
Removal and installation of KVGTassembly 50-94
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 50-98
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 50-100
Removal and installation of alternator belt 50-103
Removal and installation of fuel tank assembly 50-105
Power train 50-108
Removal and installation of transfer assembly 50-108
Disassembly and assembly of transfer assembly 50-113
Disassembly and assembly of parking brake assembly 50-145
Disassembly and assembly of differential assembly 50-153
Removal and installation of front axle assembly 50-177
Removal and installation of rear axle assembly 50-179
Disassembly and assembly of axle housing assembly 50-182
Undercarriage and frame 50-191
Removal and installation of center hinge pin 50-191
Removal and installation of counterweight assembly 50-200
Hydraulic system 50-202
Removal and installation of hydraulic tank assembly 50-202
Removal and installation of control valve assembly 50-205
Disassembly and assembly of control valve assembly 50-209
WA270-7 00-13
00 Index and foreword
Index
Removal and installation of hydraulic pump assembly 50-212
Removal and installation of HST motor1 assembly 50-216
Removal and installation of HST motor2 assembly 50-218
Disassembly and assembly of hydraulic cylinder assembly 50-220
Work equipment 50-227
Removal and installation of work equipment assembly 50-227
Cab and its attachments 50-233
Removal and installation of operator’s cab and floor frame assembly 50-233
Removal and installation of operator’s cab glass (adhered glass) 50-238
Removal and installation of operator’s seat assembly 50-246
Removal and installation of seat belt 50-248
Electrical system 50-249
Removal and installation of machine monitor assembly 50-249
Removal and installation of engine controller assembly 50-251
Removal and installation of HSTcontroller assembly 50-253
Removal and installation of air conditioner controller assembly 50-255
Removal and installation of monitor controller assembly 50-256
Removal and installation of mass air flow and temperature sensor 50-258
Removal and installation of KOMTRAX terminal assembly 50-259
Air conditioner unit 50-260
Removal and installation of air conditioner compressor 50-260
Removal and installation of air conditioner condenser 50-262
Removal and installation of air conditioner unit assembly 50-264
60 Maintenance standard60-1
Table of contents 60-2
Engine and cooling system60-3
Engine related parts 60-3
Cooling fan motor60-4
Power train60-6
Damper60-6
Transfer 60-7
Drive shaft 60-14
Axle 60-15
Differential 60-17
Limited slip differential 60-21
Final drive 60-23
Steering system 60-27
Steering column 60-27
Priority valve 60-28
Emergency steering valve 60-29
Steering cylinder 60-30
Brake system 60-32
Brake accumulator charge valve 60-32
Slack adjuster 60-33
Brake 60-34
Parking brake 60-36
Parking brake solenoid valve 60-37
Undercarriage and frame 60-38
Axle mount 60-38
Center hinge pin 60-40
Hydraulic system 60-44
Hydraulic tank 60-44
Double type gear pump 60-45
Steering and work equipment pump 60-46
Control valve 60-50
Self-pressure reducing valve 60-63
Work equipment PPC valve 60-65
Work equipment lock solenoid valve 60-67
Work equipment 60-68
00-14 WA270-7
00 Index and foreword
Index
Work equipment linkage 60-68
Bucket 60-72
Work equipment cylinder 60-74
Cab and its attachments 60-75
Cab mount 60-75
Electrical system 60-76
Bucket positioner 60-76
Fork positioner 60-77
Remote boom positioner 60-78
80 Appendix80-1
Table of contents 80-2
Air conditioner components 80-3
Precautions for refrigerant80-3
Air conditioner component 80-4
Configuration and function of refrigeration cycle80-6
Outline of refrigeration cycle80-7
Air conditioner unit 80-9
Dual pressure switch 80-14
Air conditioner controller 80-15
Compressor 80-16
Condenser 80-17
Receiver drier 80-18
Sunlight sensor 80-20
Outer temperature sensor (outside air temperature sensor) 80-21
Procedure for testing and troubleshooting 80-22
Circuit diagram and arrangement of connector pins 80-24
System diagram 80-27
Parts and connectors layout 80-30
Testing with self-diagnosis function 80-35
How to open the electrical system abnormality record screen in service mode of the machine
monitor 80-36
Testing temperature control system 80-38
Testing vent (mode) changeover 80-40
Testing FRESH/RECIRC air changeover 80-42
Testing evaporator temperature sensor 80-44
Testing relays 80-46
Troubleshooting chart 1 80-48
Troubleshooting chart 2 80-49
Information in troubleshooting table 80-51
Failure code list related to air conditioner 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit 80-55
Failure code [879BKA] A/C Outer Sensor Open Circuit 80-57
Failure code [879BKB] A/C Outer Sensor Short Circuit 80-59
Failure code [879CKA] Ventilating Sensor Open Circuit 80-61
Failure code [879CKB] Ventilating Sensor Short Circuit 80-63
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 80-65
Failure code [879EMC] Ventilation Damper Abnormality 80-67
Failure code [879FMC] Air Mix Damper Abnormality 80-70
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does
not operate) 80-73
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 80-76
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) 80-79
A-4 Troubleshooting for FRESH/RECIRC air changeover 80-82
Troubleshooting with gauge pressure 80-84
Connection of service tool 80-87
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit 80-89
WA270-7 00-15
00 Index and foreword
Index
Handling of compressor oil 80-91
90 Diagrams and drawings90-1
Table of contents 90-2
Hydraulic circuit diagram 90-3
Symbols in hydraulic circuit diagram 90-3
Hydraulic circuit diagram90-7
Electric circuit diagram 90-9
Symbols in electric circuit diagram 90-9
Electrical circuit diagram of machine body 90-13
Electrical circuit diagram of floor 90-21
Index 1

INDEX DETAILS:

Komatsu Wa270-7 Wheel Loader Service Repair Shop Manual (Sn A27001 And Up)

A
A-1 Troubleshooting for power supply and
CAN communication system (Air conditioner
does not operate) 80-73
A-2 Troubleshooting for compressor and
refrigerant system (Air is not cooled) 80-76
A-3 Troubleshooting for blower motor system
(No air comes out or air flow is abnormal) 80-79
A-4 Troubleshooting for FRESH/RECIRC air
changeover 80-82
Accelerator pedal position sensor 10-293
Adjusting rearview camera angle 30-173
Adjusting replaced, reassembled or added
sensor, controller, etc with machine monitor 30-94
Air conditioner component 80-4
Air conditioner controller 80-15
Air conditioner unit 80-9
Axle10-74, 60-15
Axle mount 10-128, 60-38
B
Bleeding air from fuel system 30-35
Bleeding air from hydraulic fan circuit 30-77
Bleeding air from wheel brake circuit 30-68
Bleeding air from work equipment circuit 30-84
Brake 10-121, 60-34
Brake accumulator 10-118
Brake accumulator charge valve 10-109, 60-32
Brake valve 10-114
Bucket 10-196, 60-72
Bucket positioner 60-76
C
Cab mount 10-199, 60-75
Center hinge pin 10-130, 60-40
Checks before troubleshooting 40-14
Circuit diagram and arrangement of connector
pins 80-24
Classification and procedures for
troubleshooting 40-39
CLSS 10-162
Clutch solenoid valve 10-71
Coating materials list50-6
Combination switch 10-296
Compressor 80-16
Condenser 80-17
Configuration and function of refrigeration
cycle 80-6
Connection of service tool 80-87
Connector contact identification 40-64
Control valve 10-152, 60-50
Conversion table 00-63
Cooling fan motor 10-30, 60-4
Cooling system 10-28
Cushion valve 10-96
D
Damper 10-43, 60-6
Differential10-76, 60-17
Disassembly and assembly of axle housing
assembly 50-182
Disassembly and assembly of control valve
assembly 50-209
Disassembly and assembly of differential
assembly 50-153
Disassembly and assembly of hydraulic
cylinder assembly 50-220
Disassembly and assembly of KDPF assembly 50-
82
Disassembly and assembly of parking brake
assembly 50-145
Disassembly and assembly of transfer
assembly 50-113
Double type gear pump 10-139, 60-45
Drive shaft10-73, 60-14
Dual pressure switch 80-14
E
E-1 Engine does not start (Engine does not
crank) 40-726
E-2 Manual preheating system does not work 40-
733
E-3 Automatic preheating system does not
work 40-736
E-4 While preheating is working, preheating
monitor does not light up 40-738
E-5 All of LCD unit, LED unit and meter unit on
machine monitor display nothing 40-740
E-6 LCD unit on machine monitor displays
nothing 40-743
E-7 Backlight of LCD unit on machine monitor
is abnormal (Backlight goes out or flickers) 40-745
E-8 LCD on machine monitor does not display
properly 40-747
E-9 Meter unit display on machine monitor is
abnormal 40-749
E-10 Night lighting lamp of meter unit on
machine monitor is abnormal 40-752
E-11 Caution LED on machine monitor is
abnormal 40-755
E-12 LED of switch panel on machine monitor
is abnormal or switches does not operate
properly 40-757
E-13 Two switches operation of switch panel
on machine monitor does not function 40-759
WA270-7 1
INDEX
E-14 Switch panel buzzer of machine monitor
is abnormal 40-762
E-15 Rearview monitor does not light up or
backlight flickers 40-764
E-16 Rearview monitor images are not
displayed clearly 40-767
E-17 Rearview monitor brightness cannot be
adjusted 40-770
E-18 Night lighting lamp of rearview monitor is
abnormal 40-773
E-19 Some items of gauges and caution lamps
on machine monitor are not displayed
properly 40-775
E-20 Parking brake indicator lamp does not
light when the parking brake is set to ON
(Parking) position 40-776
E-21 When brake accumulator oil pressure
drops, the brake oil pressure caution lamp
does not light 40-780
E-22 The HSToil filter clogging caution lamp
does not light up 40-782
E-23 Radiator coolant level caution lamp does
not light 40-784
E-24 Indication of HSToil temperature gauge
does not increase, or HSToil temperature
caution lamp does not light 40-786
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 40-787
E-26 Fuel level gauge does not indicate correct
level 40-789
E-27 Seat belt caution lamp indication is
abnormal 40-791
E-28 Horn does not sound 40-792
E-29 Horn does not stop sounding 40-795
E-30 Alarm buzzer does not sound 40-797
E-31 When starting switch is in ON position,
alarm buzzer does not stop sounding 40-799
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 40-800
E-33 Setting does not change while operating
traction control switch 40-802
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 40-804
E-35 Remote positioner does not work or
cannot be released 40-807
E-36 Bucket positioner does not work or
cannot be released 40-809
E-37 Direction selector (FNR) switch mode is
not selected or not released 40-812
E-38 PZ auto tilt-in does not work 40-814
E-39 Tracktion level does not display MAX
when max traction switch is turned ON 40-817
E-40 ECSS function cannot be selected or
cannot be released 40-819
E-41 None of headlamp, clearance lamp, and
tail lamp lights 40-821
E-42 Clearance lamp, tail lamp and licenseplate
lamp do not light up or go out 40-823
E-43 Both High and Low beams of headlamp
do not light up or go out 40-827
E-44 Low beam of headlamp does not light up
or go out 40-831
E-45 High beam of headlamp does not light up
or go out 40-833
E-46 Front working lamp does not light up or
go out 40-835
E-47 Rear working lamp does not light up or go
out 40-839
E-48 All of turn signal lamps and hazard lamps
do not flash or go out 40-843
E-49 Turn signal lamps do not flash or go out 40-846
E-50 Hazard lamp does not flash or go out 40-849
E-51 Brake lamp does not light or stays lighted 40-
852
E-52 Backup lamp does not light up or does
not go out 40-855
E-53 Backup buzzer does not sound or
continues to sound 40-858
E-54 Front wiper does not operate 40-860
E-55 Rear wiper does not operate 40-863
E-56 Window washer does not operate 40-865
E-57 KOMTRAX system does not operate
normally 40-868
ECCS accumulator charge valve 10-175
ECSS accumulator 10-194
EGR cooler 10-19
EGR system circuit diagram 10-15
EGR system piping drawing 10-13
EGR valve 10-17
Electrical circuit diagram of floor 90-21
Electrical circuit diagram of machine body 90-13
Emergency steering valve 10-97, 60-29
Engine control system 10-200
Engine controller 10-281
Engine output limit function 10-205
Engine related parts10-4, 60-3
Explanation of terms for maintenance standard 00-
26
F
Failure code [2F00MA] Failure of Parking
Brake Circuit 40-134
Failure code [2F00MB] Malfunction of Parking
Brake 40-137
Failure code [2G42ZG] Accumulator Oil
Pressure Low (Front) 40-139
Failure code [2G43ZG] Accumulator Oil
Pressure Low (Rear) 40-141
Failure code [6091NX] HST Oil Filter Clogging 40-
143
2 WA270-7
INDEX
Failure code [7RHYKA] Disconnection of Fan
Variable Control Sol 40-145
Failure code [7RHYKB] Ground Fault of Fan
Variable Control Sol 40-147
Failure code [7RHYKY] Hot Short of Fan
Variable Control Sol 40-149
Failure code [879AKA] A/C Inner Sensor Open
Circuit 40-151, 80-53
Failure code [879AKB] A/C Inner Sensor Short
Circuit 40-152, 80-55
Failure code [879BKA] A/C Outer Sensor
Open Circuit 40-153, 80-57
Failure code [879BKB] A/C Outer Sensor Short
Circuit 40-154, 80-59
Failure code [879CKA] Ventilating Sensor
Open Circuit 40-155, 80-61
Failure code [879CKB] Ventilating Sensor
Short Circuit 40-156, 80-63
Failure code [879DKZ] Sunlight Sensor Open
or Short Circuit 40-157, 80-65
Failure code [879EMC] Ventilation Damper
Abnormality 40-158, 80-67
Failure code [879FMC] Air Mix Damper
Abnormality 40-159, 80-70
Failure code [989L00] Engine Controller Lock
Caution 1 40-160
Failure code [989M00] Engine Controller Lock
Caution 2 40-161
Failure code [989N00] Engine Controller Lock
Caution 3 40-162
Failure code [A1U0N3] HC desorb request 1 40-163
Failure code [A1U0N4] HC desorb request 2 40-165
Failure code [B@BAZG]Eng Oil Press Low 40-167
Failure code [B@BCNS] Eng Water Overheat 40-
168
Failure code [B@BCZK] Eng Water Level Low 40-
169
Failure code [B@CRNS] HST Oil Temp
Overheat 40-171
Failure code [CA1117] Persistent Data Lost
Error 40-272
Failure code [CA115] Eng Ne and Bkup Speed
Sens Error 40-172
Failure code [CA122] Chg Air Press Sensor
High Error 40-173
Failure code [CA123] Chg Air Press Sensor
Low Error 40-175
Failure code [CA131] Throttle Sensor High
Error 40-177
Failure code [CA132] Throttle Sensor Low
Error 40-179
Failure code [CA144] Coolant Temp Sens High
Error 40-181
Failure code [CA145] Coolant Temp Sens Low
Error 40-183
Failure code [CA153] Chg Air Temp Sensor
High Error 40-185
Failure code [CA154] Chg Air Temp Sensor
Low Error 40-187
Failure code [CA1664] KDOC Malfunction 40-273
Failure code [CA1691] Regeneration
Ineffective 40-276
Failure code [CA1695] Sensor 5 Supply Volt
High Error 40-279
Failure code [CA1696] Sensor 5 Supply Volt
Low Error 40-280
Failure code [CA1843] Crankcase Press Sens
High Error 40-282
Failure code [CA1844] Crankcase Press Sens
Low Error 40-284
Failure code [CA187] Sensor 2 Supply Volt
Low Error 40-189
Failure code [CA1879] KDPF Delta P Sensor
High Error 40-286
Failure code [CA1881] KDPF Delta P Sensor
Low Error 40-288
Failure code [CA1883] KDPF Delta P Sens In
Range Error 40-290
Failure code [CA1921] KDPF Soot Load High
Error 1 40-294
Failure code [CA1922] KDPF Soot Load High
Error 2 40-297
Failure code [CA1942] Crankcase Press Sens
In Range Error 40-302
Failure code [CA1993] KDPF Delta Pressure
Low Error 40-303
Failure code [CA2185] Throt Sensor Sup Volt
High Error 40-306
Failure code [CA2186] Throt Sensor Sup Volt
Low Error 40-308
Failure code [CA221] Ambient Press Sensor
High Error 40-191
Failure code [CA222] Ambient Press Sensor
Low Error 40-193
Failure code [CA2249] Rail Press Very Low
Error 2 40-310
Failure code [CA227] Sensor 2 Supply Volt
High Error 40-195
Failure code [CA2271] EGR Valve Pos Sens
High Error 40-311
Failure code [CA2272] EGR Valve Pos Sens
Low Error 40-313
Failure code [CA2288] Turbo Speed High Error
1 40-316
Failure code [CA2311] IMV Solenoid Error 40-317
Failure code [CA234] Eng Overspeed 40-196
Failure code [CA2349] EGR Valve Solenoid
Open Error 40-318
Failure code [CA2353] EGR Valve Solenoid
Short Error 40-320
Failure code [CA2357] EGR Valve Servo Error 40-
322
Failure code [CA2373] Exhaust Manifold Press
Sens High Error 40-323
Failure code [CA2374] Exhaust Manifold Press
Sens Low Error 40-325
Failure code [CA2375] EGR Orifice Temp Sens
High Error 40-327
WA270-7 3
INDEX
Failure code [CA2376] EGR Orifice Temp Sens
Low Error 40-329
Failure code [CA238] Ne Speed Sensor
Supply Volt Error 40-197
Failure code [CA2381] KVGT Pos Sens High
Error 40-331
Failure code [CA2382] KVGT Pos Sens Low
Error 40-333
Failure code [CA2383] KVGT Solenoid Open
Error 40-336
Failure code [CA2386] KVGT Solenoid Short
Error 40-338
Failure code [CA2387] KVGT Servo Error 40-340
Failure code [CA239] Ne Speed Sens Supply
Volt High Error 40-198
Failure code [CA2554] Exh Manifold Press
Sens In Range Error 40-341
Failure code [CA2555] Grid Htr Relay Volt Low
Error 40-342
Failure code [CA2556] Grid Htr Relay Volt High
Error 40-344
Failure code [CA2637] KDOC Face Plugging 40-346
Failure code [CA2639] Manual Stationary
Regeneration Request 40-348
Failure code [CA271] IMV/PCV1 Short Error 40-199
Failure code [CA272] IMV/PCV1 Open Error 40-201
Failure code [CA295] Ambient Press Sens In
Range Error 40-203
Failure code [CA2961] EGR Orifice Temp High
Error 1 40-351
Failure code [CA2973] Chg Air Press Sensor
In Range Error 40-352
Failure code [CA3133] KDPF Outlet Press
Sens High Error 40-353
Failure code [CA3134] KDPF Outlet Press
Sens Low Error 40-355
Failure code [CA3135] KDPF Outlet Press
Sens In Range Error 40-357
Failure code [CA322] Inj #1(L#1) Open/Short
Error 40-204
Failure code [CA323] Inj #5(L#5) Open/Short
Error 40-206
Failure code [CA324] Inj #3(L#3) Open/Short
Error 40-208
Failure code [CA325] Inj #6(L#6) Open/Short
Error 40-210
Failure code [CA3251] KDOC Inlet Temp High
Error 40-361
Failure code [CA3253] KDOC Temp Error –
Non Regeneration 40-364
Failure code [CA3254] KDOC Outlet Temp
High Error 1 40-367
Failure code [CA3255] KDPF Temp Error – Non
Regeneration 40-370
Failure code [CA3256] KDPF Outlet Temp
High Error 1 40-373
Failure code [CA331] Inj #2(L#2) Open/Short
Error 40-212
Failure code [CA3311] KDOC Outlet Temp
High Error 2 40-376
Failure code [CA3312] KDPF Outlet Temp
High Error 2 40-379
Failure code [CA3313] KDOC Inlet Temp
Sensor Low 40-382
Failure code [CA3314] KDOC Inlet Temp
Sensor High Error 40-385
Failure code [CA3315] KDOC Inlet Temp Sens
In Range Error 40-388
Failure code [CA3316] KDOC Outlet Temp
Sens Low Error 40-392
Failure code [CA3317] KDOC Outlet Temp
Sens High Error 40-395
Failure code [CA3318] KDOC Outlet Temp
Sens In Range Error 40-398
Failure code [CA3319 KDPF Outlet Temp Sens
High Error 40-402
Failure code [CA332] Inj #4(L#4) Open/Short
Error 40-214
Failure code [CA3321] KDPF Outlet Temp
Sens Low Error 40-405
Failure code [CA3322] KDPF Outlet Temp
Sens In Range Error 40-408
Failure code [CA3419] Mass Air Flow Sensor
Sup Volt High Error 40-412
Failure code [CA3421] Mass Air Flow Sensor
Sup Volt Low Error 40-414
Failure code [CA343] ECM Critical Internal
Failure 40-216
Failure code [CA351] Injectors Drive Circuit
Error 40-217
Failure code [CA352] Sensor 1 Supply Volt
Low Error 40-218
Failure code [CA356] Mass Air Flow Sensor
High Error 40-220
Failure code [CA357] Mass Air Flow Sensor
Low Error 40-222
Failure code [CA3741] Rail Press Valve Trip
Error 40-416
Failure code [CA386] Sensor 1 Supply Volt
High Error 40-224
Failure code [CA428] Water in Fuel Sensor
High Error 40-225
Failure code [CA429] Water in Fuel Sensor
Low Error 40-227
Failure code [CA431] Idle Validation Sw Error 40-
229
Failure code [CA432] Idle Validation Process
Error 40-232
Failure code [CA435] Eng Oil Press Sw Error40-
235
Failure code [CA441] Battery Voltage Low
Error 40-236
Failure code [CA442] Battery Voltage High
Error 40-238
Failure code [CA449] Rail Press Very High
Error 40-239
4 WA270-7
INDEX
Failure code [CA451] Rail Press Sensor High
Error 40-240
Failure code [CA452] Rail Press Sensor Low
Error 40-242
Failure code [CA488] Chg Air Temp High
Torque Derate 40-244
Failure code [CA515] Rail Press Sens Sup Volt
High Error 40-245
Failure code [CA516] Rail Press Sens Sup Volt
Low Error 40-247
Failure code [CA553] Rail Press High Error 40-249
Failure code [CA555] Crankcase Press High
Error 1 40-250
Failure code [CA556] Crankcase Press High
Error 2 40-251
Failure code [CA559] Rail Press Low Error 40-252
Failure code [CA595] Turbo Speed High Error
2 40-254
Failure code [CA687] Turbo Speed Low Error 40-
255
Failure code [CA689] Eng Ne and Speed
Sensor Error 40-257
Failure code [CA691] Intake Air Temp Sens
High Error 40-259
Failure code [CA692] Intake Air Temp Sens
Low Error 40-261
Failure code [CA697] ECM Internal Temp
Sensor High Error 40-263
Failure code [CA698] ECM Int Temp Sensor
Low Error 40-264
Failure code [CA731] Eng Bkup Speed Sens
Phase Error 40-265
Failure code [CA778] Eng Bkup Speed Sensor
Error 40-267
Failure code [D110L4] Disconnection of
Battery Relay Signal 40-417
Failure code [D160KA] Disconnection of
Backup Lamp Relay Output 40-419
Failure code [D160KY] Hot Short of Backup
Lamp Relay Output 40-421
Failure code [D191KA] Disconnection of
Neutral Output Relay 40-423
Failure code [D191KB] Ground Fault of Neutral
Output Relay 40-425
Failure code [D191KY] Hot Short of Neutral
Output Relay 40-427
Failure code [D192KA] Disconnection of ECSS
Solenoid 40-429
Failure code [D192KB] Ground Fault of ECSS
Solenoid 40-431
Failure code [D192KY] Hot Short of ECSS
Solenoid 40-432
Failure code [D1B0KA] Disconnection of HST
Safety Relay 40-435
Failure code [D1B0KB] Ground Fault of HST
Safety Relay 40-437
Failure code [D1B0KY] Hot Short of HST
Safety Relay 40-439
Failure code [D1B0MC] Malfunction of HST
Safety Relay 40-441
Failure code [D1E6KA] Disconnection of
Parking Brake Relay 40-442
Failure code [D1E6KB] Ground Fault of
Parking Brake Relay 40-444
Failure code [D1E6KY] Hot Short of Parking
Brake Relay 40-446
Failure code [D5ZHKA] Failure of Key SW C
Signal 40-448
Failure code [D5ZHKB] Key SW C Signal
Short Circuit 40-450
Failure code [D5ZHL6] Disconnection of Key
SW C 40-452
Failure code [D811MC] KOMTRAX Error 40-453
Failure code [D862KA] GPS Antenna Open
Circuit 40-454
Failure code [D8ALKA] Operating Lamp Open
Circuit (KOMTRAX) 40-455
Failure code [D8ALKB] Operating Lamp Short
Circuit (KOMTRAX) 40-457
Failure code [D8AQK4] CAN2 Discon
(KOMTRAX) 2 40-459
Failure code [D8AQKR] CAN2 Discon
(KOMTRAX) 40-460
Failure code [DAF0KT] Abnormality of Nonvolatile
Memory (MON) 40-462
Failure code [DAF0MB] Monitor ROM
Abnormality 40-463
Failure code [DAF0MC] Monitor Error 40-464
Failure code [DAF3KK] Controller Power
Source Low (MON) 40-465
Failure code [DAF8KB] Camera Power Supply
Short Circuit 40-467
Failure code [DAFDKB] Monitor 12V Power
Output Short Circuit 40-468
Failure code [DAFGMC] GPS Module Error 40-469
Failure code [DAFLKA] Operating Lamp Open
Circuit (MON) 40-470
Failure code [DAFLKB] Operating Lamp Short
Circuit (MON) 40-472
Failure code [DAFQKR] CAN2 Discon
(Monitor) 40-474
Failure code [DAJ0KK] Controller Power
Source Low (T/M) 40-475
Failure code [DAJ0KT] Abnormality of Nonvolatile
Memory (HST) 40-478
Failure code [DAJ0MC] HST Con Error 40-479
Failure code [DAJ1KA] Disconnection of Key
SW ACC (HST) 40-480
Failure code [DAJ2KK] Solenoid Power
Source Low (HST) 40-482
Failure code [DAJ4KB] Ground Fault of Sol
Self-Holding Relay 40-485
Failure code [DAJ4KZ] Failure of Sol Self-
Holding Relay 40-487
Failure code [DAJ5KX] Failure of 5V Power
Source 0 40-489
WA270-7 5
INDEX
Failure code [DAJ6KX] Failure of 5V Power
Source 1 40-491
Failure code [DAJ9KQ] Inconsistency of Model
Selection (HST) 40-493
Failure code [DAJLKA] Operating Lamp Open
Circuit (HST) 40-494
Failure code [DAJLKB] Operating Lamp Short
Circuit (HST) 40-496
Failure code [DAJQKR] CAN2 Discon ( HST
Con) 40-498
Failure code [DAJRKR] CAN1 Discon ( HST
Con) 40-499
Failure code [DAJRMA] Inconsistency of
Option Selection (HST) 40-500
Failure code [DAZ9KQ] A/C Model Selection
Abnormality 40-501
Failure code [DAZQKR] CAN2 Discon (Aircon
ECU) 40-502
Failure code [DB2QKR] CAN2 Discon (Engine
Con) 40-503
Failure code [DB2RKR] CAN1 Discon (Engine
Con) 40-508
Failure code [DD1ALD] Ground Fault of
Remote Positioner Set SW 40-512
Failure code [DDAAL6] Discon of Engine
Shutdown Secondary Switch 40-514
Failure code [DDB2L4] Stop Lamp Switch
Signal Malfunction 40-516
Failure code [DDB6L4] Parking Brake Signal
Malfunction 40-518
Failure code [DDD7KA] Failure of Variable
Speed Control 40-521
Failure code [DDD7KY] Hot Short of Variable
Speed Control 40-523
Failure code [DDK3KA] FNR SW Input Signal
Disconnection 40-525
Failure code [DDK3KB] FNR SW Input Signal
Short Circuit 40-527
Failure code [DDK6KA] FNR Lever Input
Signal Disconnection 40-529
Failure code [DDK6KB] FNR Lever Input
Signal Short Circuit 40-532
Failure code [DDNRLD] Ground Fault of Work
Equip Lock Switch 40-534
Failure code [DF10KA] Disconnection of
Speed Range Input 40-536
Failure code [DF10KB] Ground Fault of Speed
Range Input 40-539
Failure code [DGR2KB] Ground Fault of Brake
Oil Temp Sensor 40-542
Failure code [DGR2KZ] Failure of Brake Oil
Temp Sensor 40-544
Failure code [DHG1KX] Out of Range of HST
Oil Temp Sensor 40-546
Failure code [DHHBKA] Failure of HST Press
Sens Circuit (MA) 40-548
Failure code [DHHBKY] Hot Short of HST
Press Sens Circuit (MA) 40-550
Failure code [DHHCKA] Failure of HST Press
Sens Circuit (MB) 40-552
Failure code [DHHCKY] Hot Short of HST
Press Sens Circuit (MB) 40-554
Failure code [DHPCKA] Failure of Boom
Press Sensor (Bottom) 40-556
Failure code [DHPCKY] Hot Short of Boom
Press Sensor (Bottom) 40-558
Failure code [DHPEKA] Failure of Steering &
Loader Pump Press 40-560
Failure code [DHPEKY] Hot Short of Steering
& Loader Pump Press 40-562
Failure code [DHS8KA] Failure of Boom Raise
PPC Sens Circuit 40-564
Failure code [DHS8KY] Hot Short of Boom
Raise PPC Sens Circuit 40-566
Failure code [DHS9KA] Failure of Boom Lower
PPC Sens Circuit 40-568
Failure code [DHS9KY] Hot Short of Boom
Lower PPC Sens Circuit 40-570
Failure code [DHSDKA] Failure of Bucket
Dump PPC Sens Circuit 40-572
Failure code [DHSDKY] Hot Short of Bucket
Dump PPC Sens Circuit 40-574
Failure code [DHSNKA] Failure of Bucket Tilt
PPC Sens Circuit 40-576
Failure code [DHSNKY] Hot Short of Bucket
Tilt PPC Sens Circuit 40-578
Failure code [DHT8ZG] Steering Oil Pressure
Low 40-580
Failure code [DHTCL6] Failure of HST Oil Filter
Sensor Circuit 40-581
Failure code [DJF1KA] Disconnection of Fuel
Level Sensor 40-583
Failure code [DK55KA] Failure of FNR Lever
Potentio 40-585
Failure code [DK55KY] Hot Short of FNR Lever
Potentio Circuit 40-588
Failure code [DK55L5] Failure of FNR Lever
Potentio 40-590
Failure code [DK5DKA] Failure of 3rd Lever
Potentio (Main) 40-591
Failure code [DK5DKY] Hot Short of 3rd Lever
Potentio (Main) 40-594
Failure code [DK5DL8] 3rd Lever Potentio
(Main & Sub) Disagree 40-597
Failure code [DK5EKA] Failure of 3rd Lever
Potentio (Sub) 40-600
Failure code [DK5EKY] Hot Short of 3rd Lever
Potentio (Sub) 40-603
Failure code [DK70KA] Failure of Inching
Sensor Circuit 40-606
Failure code [DK70KY] Hot Short of Inching
Sensor Circuit 40-609
Failure code [DKA0KA] Failure of Boom Angle
Sensor 40-611
Failure code [DKA0KY] Hot Short of Boom
Angle Sensor Circuit 40-613
6 WA270-7
INDEX
Failure code [DKA0L0] Boom Angle Sensor
Dislocation 40-615
Failure code [DLM3KA] Disconnection of
Radiator Fan Speed Sensor 40-617
Failure code [DLM3LC] Failure of Radiator Fan
Speed Sensor 40-619
Failure code [DLT3KX] Vehicle Speed Sensor
Circuit Failure (B) 40-621
Failure code [DLT4KX] Vehicle Speed Sensor
Circuit Failure (A) 40-623
Failure code [DLT4L0] Vehicle Speed Sensor
Failure (A & B) 40-625
Failure code [DLT4LC] Vehicle Speed Sensor
Failure (A or B) 40-628
Failure code [DPQ1KR] LIN Discon (Switch
Panel) 40-630
Failure code [DPQ2KR] LIN Discon (LED Unit)40-
633
Failure code [DPQ3KR] LIN Discon (Rear View
Monitor) 40-636
Failure code [DSJ0KR] CAN2 Discon (Meter
Unit) 40-639
Failure code [DT22KB] Ground Fault of Work
Equip Lock Indic 40-641
Failure code [DV00KB] Ground Fault of Buzzer
Output 40-643
Failure code [DW26KA] Disconnection of
Motor 2 Solenoid 40-645
Failure code [DW26KB] Ground Fault of Motor
2 Solenoid 40-647
Failure code [DW26KY] Hot Short of Motor 2
Solenoid 40-649
Failure code [DW4BKA] Disconnection of
Parking Brake Valve 40-651
Failure code [DW4BKB] Ground Fault of
Parking Brake Valve 40-653
Failure code [DW4BKY] Hot Short of Parking
Brake Valve 40-655
Failure code [DW4RKA] Disconnection of
Bucket EPC Sol (Tilt) 40-656
Failure code [DW4RKB] Ground Fault of
Bucket EPC Solenoid (Tilt) 40-658
Failure code [DW4RKY] Hot Short of Bucket
EPC Solenoid (Tilt) 40-660
Failure code [DWM1KA] Disconnection of
Neutral Lock Solenoid 40-661
Failure code [DWM1KB] Ground Fault of
Neutral Lock Solenoid 40-663
Failure code [DWM1KY] Hot Short of Neutral
Lock Solenoid 40-665
Failure code [DWN6KA] Disconnection of
Detent Solenoid (Boom) 40-666
Failure code [DWN6KB] Ground Fault of
Detent Solenoid (Boom) 40-668
Failure code [DWN6KY] Hot Short of Detent
Solenoid (Boom) 40-670
Failure code [DWN8KA] Disconnection of
Detent Solenoid (Bucket) 40-672
Failure code [DWN8KB] Ground Fault of
Detent Solenoid (Bucket) 40-674
Failure code [DWN8KY] Hot Short of Detent
Solenoid (Bucket) 40-676
Failure code [DX19KA] Disconnection of Motor
1 Solenoid 40-677
Failure code [DX19KB] Ground Fault of Motor
1 Solenoid 40-679
Failure code [DX19KY] Hot Short of Motor 1
Solenoid 40-681
Failure code [DX20KA] Disconnection of
Clutch Control Solenoid 40-683
Failure code [DX20KB] Ground Fault of Clutch
Control Solenoid 40-685
Failure code [DX20KY] Hot Short of Clutch
Control Solenoid 40-687
Failure code [DXAWKA] Disconnection of HST
Pump EPC Sol 40-689
Failure code [DXAWKB] Ground Fault of HST
Pump EPC Sol 40-691
Failure code [DXAWKY] Hot Short of HST
Pump EPC Sol 40-693
Failure code [DXH7KA] Disconnection of
Reverse Solenoid 40-695
Failure code [DXH7KB] Ground Fault of
Reverse Solenoid 40-697
Failure code [DXH7KY] Hot Short of Reverse
Solenoid 40-699
Failure code [DXH8KA] Disconnection of
Forward Solenoid 40-701
Failure code [DXH8KB] Ground Fault of
Forward Solenoid 40-703
Failure code [DXH8KY] Hot Short of Forward
Solenoid 40-705
Failure code [DXHJKA] Disconnection of 3rd
EPC Solenoid (EXT) 40-707
Failure code [DXHJKB] Ground Fault of 3rd
EPC Solenoid (EXT) 40-709
Failure code [DXHJKY] Hot Short of 3rd EPC
Solenoid (EXT) 40-711
Failure code [DXHKKA] Disconnection of 3rd
EPC Solenoid (RET) 40-712
Failure code [DXHKKB] Ground Fault of 3rd
EPC Solenoid (RET) 40-714
Failure code [DXHKKY] Hot Short of 3rd EPC
Solenoid (RET) 40-716
Failure code [H2K0KA] Failure of Quick
Coupler Lock Signal 40-717
Failure code [H2K0KY] Hot Short of Quick
Coupler Lock Signal 40-720
Failure code [J141N1] Steering Pump Over
Run 40-722
Failure code [LA00L3] Failure of Fan Reverse40-
723
Failure code [M100N1] HST Pump Over Run 40-724
Failure code [M400N1] HST Motor 1 Over Run40-
725
Failure code list related to air conditioner 80-52
Fan 100% setting function 10-233
WA270-7 7
INDEX
Final drive 10-87, 60-23
Fork positioner 60-77
Front brake oil pressure switch 10-300
H
H-1 Machine does not travel forward or
backward 40-880
H-2 Machine does not travel forward (Machine
travels backward normally) 40-883
H-3 Machine does not travel backward
(Machine travels forward normally) 40-884
H-4 Machine does not travel forward or
backward fast 40-885
H-5 Machine does not travel forward fast
(Machine travel backward fast) 40-889
H-6 Machine does not travel backward fast
(Machine travels forward fast) 40-890
H-7 Machine lacks power neither when
traveling forward nor backward 40-891
H-8 Machine lacks power when traveling
forward (Machine has sufficient power when
traveling backward) 40-894
H-9 Machine lacks power when traveling
backward (Machine has sufficient power
when traveling forward) 40-895
H-10 Engine stalls during travel or engine
speed drops significantly 40-896
H-11 Steering wheel is too heavy to turn 40-897
H-12 Steering wheel is heavy to turn 40-899
H-13 Machine sways or large shocks are made
while machine turns 40-900
H-14 Machine unintentionally turns when
machine travels 40-901
H-15 Wheel brakes do not work or are weak 40-902
H-16 Wheel brakes are not released or drag 40-903
H-17 Parking brake does not work or it is weak40-
904
H-18 Parking brake is not released or drags 40-905
H-19 Boom does not rise 40-906
H-20 Boom moves slow or boom lacks lifting
force 40-908
H-21 Rising boom slows down at certain height40-
910
H-22 Lift cylinders do not serve to hold bucket
on ground (bucket rises off ground) 40-911
H-23 Hydraulic drift of boom is large 40-912
H-24 Boom moves up and down during
operation 40-913
H-25 Bucket does not tilt back 40-914
H-26 Bucket moves slow or lacks tilt-back
force 40-916
H-27 Bucket decelerates during tilt-back
operation 40-918
H-28 Bucket cylinder does not hold bucket on
ground 40-919
H-29 Hydraulic drift of bucket is large 40-920
H-30 Bucket tilts back and forth during carrying
load (work equipment valve in HOLD) 40-921
H-31 Boom and bucket control levers do not
move smoothly and are heavy to move 40-922
H-32 Operating work equipment causes
engine speed to lower significantly or engine
to stall 40-923
H-33 Large shocks are made when work
equipment starts to move and stops 40-924
H-34 When single work equipment is relieved
hydraulically, other work equipment moves 40-925
H-35 ECSS (travel damper) does not work and
machine pitches and bounces 40-926
H-36 Fan speed is abnormal (too high or low,
or fan does not rotate) 40-927
H-37 Unusual noise is heard from around fan40-
929
Handling battery disconnect switch 30-175
Handling cylinder cutout mode operation 30-38
Handling equipment of fuel system devices 00-28
Handling no injection cranking operation 30-39
Handling of compressor oil 80-91
Handling of electrical equipment 00-35
Handling of hydraulic equipment 00-30
Handling of intake system parts 00-29
Handling voltage circuit of engine controller 30-174
How to open the electrical system abnormality
record screen in service mode of the machine
monitor 80-36
How to read electric wire code 00-43
How to read the shop manual 00-24
How to read this manual50-4
HSTcontroller system 10-214
HST motor1 10-57
HST motor2 10-59
HST pump 10-44
Hydraulic circuit diagram 90-7
Hydraulic circuit diagram and names of valves 10-
166
Hydraulic component layout 10-133
Hydraulic tank 10-136, 60-44
I
Important safety notice 00-17
Inching pedal angle sensor 10-295
Information described in troubleshooting table
(H-mode) 40-870
Information described in troubleshooting table
(S mode) 40-930
Information in troubleshooting table 80-51
Inspection procedure before troubleshooting 40-16
K
KCCV layout drawing 10-20
KCCV ventilator 10-22
KDPF 10-24
KOMTRAX system 10-278
KVGT 10-6
8 WA270-7
INDEX
L
Layout of brake parts 10-107
Layout of power train parts 10-42
Layout of steering devices 10-90
Limited slip differential 60-21
List of abbreviation 00-58
LS bypass plug 10-169
LS valve 10-148
M
Machine monitor system 10-254
Method of disconnecting and connecting of
push-pull type coupler 00-32
Method of releasing parking brake manually 30-73
O
Orbitrol valve 10-100
Outer temperature sensor (outside air
temperature sensor) 80-21
Outline of refrigeration cycle 80-7
P
Parking brake 10-125, 60-36
Parking brake control 10-124
Parking brake control system 10-207
Parking brake oil pressure switch 10-301
Parking brake solenoid valve 10-126, 60-37
Parts and connectors layout 80-30
Pm Clinic service 30-177
Power train system 10-40
PPC circuit accumulator 10-193
Practical use of KOMTRAX 00-51
Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit 80-89
Precautions for KDPF (KCSF and KDOC)
Cleaning and Replacement 40-110
Precautions for refrigerant 80-3
Precautions on troubleshooting of machine
monitor 40-113
Precautions when performing operation 00-46
Preheating system 10-203
Preparation for troubleshooting of electrical
system 40-33
Preparation of dummy temperature sensor (for
KDOC and KDPF temperature sensors) 40-120
Preparation of short circuit electrical connector
(for failure codes [CA1883] and [CA3135]) 40-121
Pressure compensation valve 10-171
Priority valve 10-92, 60-28
Procedure for testing and troubleshooting 80-22
Procedure for troubleshooting wiring harness
of pressure sensor system for open circuit 40-47
R
Rear brake oil pressure switch 10-300
Rearview monitor system 10-275
Receiver drier 80-18
Releasing remaining pressure in brake
accumulator circuit 30-69
Remote boom positioner 60-78
Removal and installation of aftercooler 50-61
Removal and installation of air cleaner
assembly 50-92
Removal and installation of air conditioner
compressor 50-260
Removal and installation of air conditioner
condenser 50-262
Removal and installation of air conditioner
controller assembly 50-255
Removal and installation of air conditioner unit
assembly 50-264
Removal and installation of alternator belt 50-103
Removal and installation of center hinge pin 50-191
Removal and installation of control valve
assembly 50-205
Removal and installation of cooling fan and fan
motor assembly 50-76
Removal and installation of counterweight
assembly 50-200
Removal and installation of cylinder head
assembly 50-46
Removal and installation of EGR (Exhaust Gas
Recirculation) cooler assembly 50-100
Removal and installation of EGR (Exhaust Gas
Recirculation) valve assembly 50-98
Removal and installation of engine assembly 50-64
Removal and installation of engine controller
assembly 50-251
Removal and installation of engine front oil
seal 50-70
Removal and installation of engine hood
assembly 50-53
Removal and installation of engine rear oil seal 50-
73
Removal and installation of front axle assembly50-
177
Removal and installation of fuel tank assembly50-
105
Removal and installation of grille assembly 50-56
Removal and installation of HSTcontroller
assembly 50-253
Removal and installation of HST motor1
assembly 50-216
Removal and installation of HST motor2
assembly 50-218
Removal and installation of hydraulic oil cooler50-
63
Removal and installation of hydraulic pump
assembly 50-212
Removal and installation of hydraulic tank
assembly 50-202
WA270-7 9
INDEX
Removal and installation of injector assembly 50-37
Removal and installation of KCCV assembly 50-91
Removal and installation of KDPF assembly 50-78
Removal and installation of KOMTRAX
terminal assembly 50-259
Removal and installation of KVGTassembly 50-94
Removal and installation of machine monitor
assembly 50-249
Removal and installation of mass air flow and
temperature sensor 50-258
Removal and installation of monitor controller
assembly 50-256
Removal and installation of operator’s cab and
floor frame assembly 50-233
Removal and installation of operator’s cab
glass (adhered glass) 50-238
Removal and installation of operator’s seat
assembly 50-246
Removal and installation of radiator core
assembly 50-58
Removal and installation of rear axle assembly 50-
179
Removal and installation of seat belt 50-248
Removal and installation of supply pump
assembly 50-33
Removal and installation of transfer assembly 50-
108
Removal and installation of work equipment
assembly 50-227
Replacing alternator belt 30-44
ROPS cab 10-197
S
S-1 Engine does not crank when starting
switch is turned to START position 40-931
S-2 Engine cranks but no exhaust smoke
comes out 40-932
S-3 Fuel is being injected but engine does not
start (misfiring: engine cranks but does not
start) 40-933
S-4 Engine startability is poor 40-934
S-5 Engine does not pick up smoothly 40-936
S-6 Engine stops during operation 40-938
S-7 Engine runs rough or is unstable 40-940
S-8 Engine lacks power 40-941
S-9 KDPF gets clogged in a short time 40-943
S-10 Engine oil consumption is excessive 40-945
S-11 Engine oil becomes contaminated early 40-946
S-12 Fuel consumption is excessive 40-947
S-13 Oil is in coolant (or coolant spurts or
coolant level goes down) 40-948
S-14 Oil pressure drops 40-949
S-15 Fuel mixes into engine oil 40-950
S-16 Water mixes into engine oil (milky) 40-951
S-17 Coolant temperature rises too high
(overheating) 40-952
S-18 Unusual noise is heard 40-953
S-19 Vibration is excessive 40-954
S-20 Air cannot be bled from fuel circuit 40-956
S-21 Active regeneration is executed
frequently 40-957
S-22 Active regeneration takes time 40-958
S-23 White smoke is exhausted during active
regeneration 40-959
Self-pressure reducing valve 10-179, 60-63
Sensor 10-304
Sequence of events in troubleshooting 40-12
Servo valve 10-146
Sketch of tools for testing and adjusting 30-10
Sketches of special tools 50-17
Slack adjuster 10-119, 60-33
Special functions of machine monitor 30-95
Special tools list 50-10
Specification drawing 01-3
Specifications01-5
Standard tightening torque table 00-52
Standard value table for electrical system 20-17
Standard value table for engine20-3
Standard value table for machine 20-5
Steering and work equipment pump 10-140, 60-46
Steering column 10-91, 60-27
Steering cylinder 60-30
Sunlight sensor 80-20
Symbols in electric circuit diagram90-9
Symbols in hydraulic circuit diagram90-3
System component parts 10-281
System diagram 80-27
System operating lamp function 10-211
T
T-branch box and T-branch adapter table 40-102
Table of fuel, coolant, and lubricants 01-12
Testing accelerator pedal 30-47
Testing and adjusting air conditioner
compressor belt tension 30-43
Testing and adjusting boom position detection
lever 30-93
Testing and adjusting HSToil pressure 30-48
Testing and adjusting of accumulator charge
pressure 30-62
Testing and adjusting steering circuit oil
pressure 30-57
Testing and adjusting valve clearance 30-17
Testing and adjusting work equipment oil
pressure 30-80
Testing and adjusting work equipment PPC oil
pressure 30-78
Testing blowby pressure 30-23
Testing boost pressure 30-12
Testing brake pedal 30-60
Testing braking performance 30-61
Testing compression pressure 30-19
Testing cooling fan pump circuit oil pressure 30-75
Testing cooling fan speed 30-74
Testing diodes 30-176
Testing directional lever 30-52
10 WA270-7
INDEX
Testing drive shaft for looseness, backlash,
and damage 30-46
Testing ECSS accumulator nitrogen gas
pressure and procedure for charging
accumulator with nitrogen gas 30-87
Testing EGR valve and KVGT driving oil
pressure 30-25
Testing engine oil pressure 30-24
Testing engine piping for damage and
looseness 30-42
Testing engine speed 30-11
Testing evaporator temperature sensor 80-44
Testing exhaust gas color 30-15
Testing exhaust gas temperatureTesting
exhaust gas temperature 30-14
Testing FRESH/RECIRC air changeover 80-42
Testing fuel circuit for leakage 30-37
Testing fuel discharge, return and leakage 30-30
Testing fuel pressure 30-26
Testing lowering of wheel brake pressure 30-65
Testing of installed condition of cylinder heads
and manifolds 30-41
Testing of KDPF and muffler stack for
looseness and damage 30-40
Testing oil leakage from axle final drive 30-45
Testing parking brake performance 30-70
Testing parking brake release pressure 30-72
Testing relays 80-46
Testing steering wheel 30-53
Testing temperature control system 80-38
Testing transfer clutch control pressure 30-51
Testing vent (mode) changeover 80-40
Testing wear of parking brake disc 30-71
Testing wear of wheel brake disc 30-67
Testing wheel brake oil pressure 30-64
Testing with self-diagnosis function 80-35
Testing work equipment control lever 30-55
Tire 10-131
Tools for testing and adjusting30-4
Torque proportional differential 10-80
Transfer 10-64, 60-7
Troubleshooting chart 1 80-48
Troubleshooting chart 2 80-49
Troubleshooting points 40-10
Troubleshooting with gauge pressure 80-84
W
Weight table 01-10
Work equipment control 10-135
Work equipment cylinder 60-74
Work equipment linkage 10-195, 60-68
Work equipment lock solenoid valve 10-192, 60-67
Work equipment PPC valve 10-184, 60-65
Work equipment valve (boom) 10-167
Work equipment valve (bucket, service) 10-168
WA270-7 11
WA270

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