Komatsu WA270-7 WHEEL LOADER Shop Manual CEBM027601 PDF

Description

Komatsu WA270-7 WHEEL LOADER Shop Manual CEBM027601 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu WA270-7 WHEEL LOADER Shop Manual CEBM027601 –  PDF DOWNLOAD

Language : English
Pages : 2059
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA270-7 WHEEL LOADER Shop Manual CEBM027601 –  PDF DOWNLOAD

• SERIAL NUMBERS WA270-7 A27001 and up

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 and adjusting valve clearance 459
Testing compression pressure 461
Testing blowby pressure 465
Testing engine oil pressure 466
Testing EGR valve and KVGT oil pressures 467
Testing fuel pressure 468
Testing fuel discharge, return and leakage 472
Bleeding air from fuel system 477
Testing fuel circuit for leakage 479
Handling cylinder cutout mode operation 480
Handling no-injection cranking operation 481
Testing of KDPF and muffler stack for looseness and damage 482
Testing of installed condition of cylinder heads and manifolds 483
Testing engine piping for damage and looseness 484
Testing and adjusting air conditioner compressor belt tension 485
Replacing alternator belt 486
Power train 487
Testing oil leakage from axle final drive 487
Testing drive shaft for looseness, backlash, and damage 488
Testing accelerator pedal 489
Testing and adjusting HST oil pressure 490
Testing transfer clutch control pressure 493
Steering system 494
Testing directional lever 494
Testing steering wheel 495
Testing work equipment control lever 497
Testing and adjusting steering circuit oil pressure 499
Bleeding air from steering cylinder circuit 501
Brake system 502
Testing brake pedal 502
Testing braking performance 503
Testing and adjusting of accumulator charge pressure 504
Testing wheel brake oil pressure 506
Testing lowering of wheel brake pressure 507
Testing wear of wheel brake disc 509
Bleeding air from wheel brake circuit 510
Releasing remaining pressure in brake accumulator circuit 511
Testing parking brake performance 512
Testing wear of parking brake disc 513
Testing parking brake release pressure 514
Method of releasing parking brake manually 515
Hydraulic system 516
Testing cooling fan speed 516
Testing cooling fan pump circuit oil pressure 517
Bleeding air from hydraulic fan circuit 519
Testing and adjusting work equipment PPC oil pressure 520
Testing and adjusting work equipment oil pressure 522
Bleeding air from work equipment circuit 526
Releasing remaining pressure from work equipment circuit 527
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 529
Work equipment 533
Testing and adjusting bucket positioner and bucket proximity switch 533
Testing and adjusting boom position detection lever 535
Electrical system 536
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 536
Special functions of machine monitor 537
Adjusting rearview camera angle 615
Handling voltage circuit of engine controller 616
Handling battery disconnect switch 617
Testing diodes 618
Pm clinic 619
Pm Clinic service 619
Check sheet 620
40 Troubleshooting 625
Table of contents 626
Related information on troubleshooting 635
Troubleshooting points 635
Sequence of events in troubleshooting 637
Checks before troubleshooting 639
Inspection procedure before troubleshooting 641
Preparation for troubleshooting of electrical system 658
Classification and procedures for troubleshooting 664
Symptom and troubleshooting numbers 667
Information described in troubleshooting table 670
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit 672
Connector list and layout 675
Connector contact identification 689
T-branch box and T-branch adapter table 728
Fuse location table 733
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 736
Precautions when performing troubleshooting of machine monitor 739
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit 741
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 746
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 747
Failure codes table 748
Troubleshooting by failure code (Display of code) 760
Failure code [2F00MA] Failure of Parking Brake Circuit 760
Failure code [2F00MB] Malfunction of Parking Brake 763
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 765
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 767
Failure code [6091NX] HST Oil Filter Clogging 769
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol 771
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol 773
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol 775
Failure code [879AKA] A/C Inner Sensor Open Circuit 777
Failure code [879AKB] A/C Inner Sensor Short Circuit 778
Failure code [879BKA] A/C Outer Sensor Open Circuit 779
Failure code [879BKB] A/C Outer Sensor Short Circuit 780
Failure code [879CKA] Ventilating Sensor Open Circuit 781
Failure code [879CKB] Ventilating Sensor Short Circuit 782
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 783
Failure code [879EMC] Ventilation Damper Abnormality 784
Failure code [879FMC] Air Mix Damper Abnormality 785
Failure code [989L00] Engine Controller Lock Caution 1 786
Failure code [989M00] Engine Controller Lock Caution 2 787
Failure code [989N00] Engine Controller Lock Caution 3 788
Failure code [A1U0N3] HC Desorb Request 1 789
Failure code [A1U0N4] HC Desorb Request 2 791
Failure code [AB00KE] Charge Voltage Low 793
Failure code [AB00KY] Hot Short of Alternator R Terminal 794
Failure code [B@BAZG] Eng Oil Press Low 795
Failure code [B@BCNS] Eng Water Overheat 796
Failure code [B@BCZK] Eng Water Level Low 797
Failure code [B@CRNS] HST Oil Temp Overheat 799
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 800
Failure code [CA122] Chg Air Press Sensor High Error 801
Failure code [CA123] Chg Air Press Sensor Low Error 803
Failure code [CA131] Throttle Sensor High Error 805
Failure code [CA132] Throttle Sensor Low Error 807
Failure code [CA144] Coolant Temp Sens High Error 809
Failure code [CA145] Coolant Temp Sens Low Error 811
Failure code [CA153] Chg Air Temp Sensor High Error 813
Failure code [CA154] Chg Air Temp Sensor Low Error 815
Failure code [CA187] Sensor 2 Supply Volt Low Error 817
Failure code [CA221] Ambient Press Sensor High Error 819
Failure code [CA222] Ambient Press Sensor Low Error 821
Failure code [CA227] Sensor 2 Supply Volt High Error 823
Failure code [CA234] Eng Overspeed 824
Failure code [CA238] Ne Speed Sensor Supply Volt Error 825
Failure code [CA239] Ne Speed Sens Supply Volt High Error 826
Failure code [CA271] IMV/PCV1 Short Error 827
Failure code [CA272] IMV/PCV1 Open Error 829
Failure code [CA295] Ambient Press Sens In Range Error 831
Failure code [CA322] Inj #1(L#1) Open/Short Error 832
Failure code [CA323] Inj #5(L#5) Open/Short Error 834
Failure code [CA324] Inj #3(L#3) Open/Short Error 836
Failure code [CA325] Inj #6(L#6) Open/Short Error 838
Failure code [CA331] Inj #2(L#2) Open/Short Error 840
Failure code [CA332] Inj #4(L#4) Open/Short Error 842
Failure code [CA343] ECM Critical Internal Failure 844
Failure code [CA351] Injectors Drive Circuit Error 845
Failure code [CA352] Sensor 1 Supply Volt Low Error 846
Failure code [CA356] Mass Air Flow Sensor High Error 848
Failure code [CA357] Mass Air Flow Sensor Low Error 850
Failure code [CA386] Sensor 1 Supply Volt High Error 852
Failure code [CA428] Water in Fuel Sensor High Error 853
Failure code [CA429] Water in Fuel Sensor Low Error 855
Failure code [CA431] Idle Validation Sw Error 857
Failure code [CA432] Idle Validation Process Error 860
Failure code [CA435] Eng Oil Press Sw Error 863
Failure code [CA441] Battery Voltage Low Error 864
Failure code [CA442] Battery Voltage High Error 866
Failure code [CA449] Rail Press Very High Error 867
Failure code [CA451] Rail Press Sensor High Error 868
Failure code [CA452] Rail Press Sensor Low Error 870
Failure code [CA488] Chg Air Temp High Torque Derate 872
Failure code [CA515] Rail Press Sens Sup Volt High Error 873
Failure code [CA516] Rail Press Sens Sup Volt Low Error 875
Failure code [CA553] Rail Press High Error 877
Failure code [CA555] Crankcase Press High Error 1 878
Failure code [CA556] Crankcase Press High Error 2 879
Failure code [CA559] Rail Press Low Error 880
Failure code [CA595] Turbo Speed High Error 2 882
Failure code [CA687] Turbo Speed Low Error 883
Failure code [CA689] Eng Ne Speed Sensor Error 885
Failure code [CA691] Intake Air Temp Sens High Error 887
Failure code [CA692] Intake Air Temp Sens Low Error 889
Failure code [CA697] ECM Internal Temp Sensor High Error 891
Failure code [CA698] ECM Int Temp Sensor Low Error 892
Failure code [CA731] Eng Bkup Speed Sens Phase Error 893
Failure code [CA778] Eng Bkup Speed Sensor Error 895
Failure code [CA1117] Persistent Data Lost Error 900
Failure code [CA1664] KDOC Malfunction 901
Failure code [CA1691] Regeneration Ineffective 904
Failure code [CA1695] Sensor 5 Supply Volt High Error 907
Failure code [CA1696] Sensor 5 Supply Volt Low Error 908
Failure code [CA1843] Crankcase Press Sens High Error 910
Failure code [CA1844] Crankcase Press Sens Low Error 912
Failure code [CA1879] KDPF Delta P Sensor High Error 914
Failure code [CA1881] KDPF Delta P Sensor Low Error 916
Failure code [CA1883] KDPF Delta P Sens In Range Error 918
Failure code [CA1921] KDPF Soot Load High Error 1 922
Failure code [CA1922] KDPF Soot Load High Error 2 925
Failure code [CA1942] Crankcase Press Sens In Range Error 930
Failure code [CA1993] KDPF Delta Pressure Low Error 931
Failure code [CA2185] Throt Sensor Sup Volt High Error 934
Failure code [CA2186] Throt Sensor Sup Volt Low Error 936
Failure code [CA2249] Rail Press Very Low Error 938
Failure code [CA2271] EGR Valve Pos Sens High Error 939
Failure code [CA2272] EGR Valve Pos Sens Low Error 941
Failure code [CA2288] Turbo Speed High Error 1 944
Failure code [CA2311] IMV Solenoid Error 945
Failure code [CA2349] EGR Valve Solenoid Open Error 946
Failure code [CA2353] EGR Valve Solenoid Short Error 948
Failure code [CA2357] EGR Valve Servo Error 950
Failure code [CA2373] Exhaust Manifold Press Sens High error 951
Failure code [CA2374] Exhaust Manifold Press Sens Low error 953
Failure code [CA2375] EGR Orifice Temp Sens High Error 955
Failure code [CA2376] EGR Orifice Temp Sens Low Error 957
Failure code [CA2381] KVGT Pos Sens High Error 959
Failure code [CA2382] KVGT Pos Sens Low Error 961
Failure code [CA2383] KVGT Solenoid Open Error 964
Failure code [CA2386] KVGT Solenoid Short Error 966
Failure code [CA2387] KVGT Servo Error 968
Failure code [CA2554] Exh Manifold Press Sens In Range Error 969
Failure code [CA2555] Grid Htr Relay Volt Low Error 970
Failure code [CA2556] Grid Htr Relay Volt High Error 972
Failure code [CA2637] KDOC Face Plugging 974
Failure code [CA2639] Manual Stationary Regeneration Request 976
Failure code [CA2961] EGR Orifice Temp High Error 1 979
Failure code [CA2973] Chg Air Press Sensor In Range Error 980
Failure code [CA3133] KDPF Outlet Press Sens High Error 981
Failure code [CA3134] KDPF Outlet Press Sens Low Error 983
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 985
Failure code [CA3251] KDOC Inlet Temp High Error 989
Failure code [CA3253] KDOC Temp Error – Non Regeneration 992
Failure code [CA3254] KDOC Outlet Temp High Error 1 995
Failure code [CA3255] KDPF Temp Error – Non Regeneration 998
Failure code [CA3256] KDPF Outlet Temp High Error 1 1001
Failure code [CA3311] KDOC Outlet Temp High Error 2 1004
Failure code [CA3312] KDPF Outlet Temp High Error 2 1007
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 1010
Failure code [CA3314] KDOC Inlet Temp Sens High Error 1013
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 1016
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 1020
Failure code [CA3317] KDOC Outlet Temp Sens High Error 1023
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 1026
Failure code [CA3319] KDPF Outlet Temp Sens High Error 1030
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 1033
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 1036
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 1040
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 1042
Failure code [CA3741] Rail Press Valve Trip Error 1044
Failure code [D110L4] Disconnection of Battery Relay Signal 1045
Failure code [D160KA] Disconnection of Backup Lamp Relay Output 1047
Failure code [D160KY] Hot Short of Backup Lamp Relay Output 1049
Failure code [D191KA] Disconnection of Neutral Output Relay 1051
Failure code [D191KB] Ground Fault of Neutral Output Relay 1053
Failure code [D191KY] Hot Short of Neutral Output Relay 1055
Failure code [D192KA] Disconnection of ECSS Solenoid 1057
Failure code [D192KB] Ground Fault of ECSS Solenoid 1059
Failure code [D192KY] Hot Short of ECSS Solenoid 1060
Failure code [D19JKZ] Personal Code Relay Abnormality 1061
Failure code [D1B0KA] Disconnection of HST Safety Relay 1063
Failure code [D1B0KB] Ground Fault of HST Safety Relay 1065
Failure code [D1B0KY] Hot Short of HST Safety Relay 1067
Failure code [D1B0MC] Malfunction of HST Safety Relay 1069
Failure code [D1E6KA] Disconnection of Parking Brake Relay 1070
Failure code [D1E6KB] Ground Fault of Parking Brake Relay 1072
Failure code [D1E6KY] Hot Short of Parking Brake Relay 1074
Failure code [D5ZHKA] Failure of Key SW C Signal 1076
Failure code [D5ZHKB] Key SW C Signal Short Circuit 1078
Failure code [D5ZHL6] Disconnection of Key SW C 1080
Failure code [D811MC] KOMTRAX Error 1081
Failure code [D862KA] GPS Antenna Open Circuit 1082
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 1083
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 1085
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 1087
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 1088
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 1090
Failure code [DAF0MB] Monitor ROM Abnormality 1091
Failure code [DAF0MC] Monitor Error 1092
Failure code [DAF3KK] Controller Power Source Low (MON) 1093
Failure code [DAF8KB] Camera Power Supply Short Circuit 1095
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 1096
Failure code [DAFGMC] GPS Module Error 1097
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) 1098
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 1100
Failure code [DAFQKR] CAN2 Discon (Monitor) 1102
Failure code [DAJ0KK] Controller Power Source Low (HST) 1103
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) 1106
Failure code [DAJ0MC] HST Con Error 1107
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) 1108
Failure code [DAJ2KK] Solenoid Power Source Low (HST) 1110
Failure code [DAJ4KB] Ground Fault of Sol Self-Holding Relay 1113
Failure code [DAJ4KZ] Failure of Sol Self-Holding Relay 1115
Failure code [DAJ5KX] Failure of 5V Power Source 0 1117
Failure code [DAJ6KX] Failure of 5V Power Source 1 1119
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) 1121
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) 1122
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) 1124
Failure code [DAJQKR] CAN2 Discon ( HST Con) 1126
Failure code [DAJRKR] CAN1 Discon ( HST Con) 1127
Failure code [DAJRMA] Inconsistency of Option Selection (HST) 1128
Failure code [DAZ9KQ] A/C Model Selection Abnormality 1129
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1130
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1131
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1136
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW 1140
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 1142
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction 1144
Failure code [DDB6L4] Parking Brake Signal Malfunction 1146
Failure code [DDD7KA] Failure of Variable Speed Control 1149
Failure code [DDD7KY] Hot Short of Variable Speed Control 1151
Failure code [DDK3KA] FNR SW Input Signal Disconnection 1153
Failure code [DDK3KB] FNR SW Input Signal Short Circuit 1155
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 1157
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit 1160
Failure code [DDNRLD] Ground Fault of Work Equip Lock Switch 1162
Failure code [DF10KA] Disconnection of Speed Range Input 1164
Failure code [DF10KB] Ground Fault of Speed Range Input 1167
Failure code [DGH1KX] Out of Range of HST Oil Temp Sensor 1170
Failure code [DGR2KB] Ground Fault of Brake Oil Temp Sensor 1172
Failure code [DGR2KZ] Failure of Brake Oil Temp Sensor 1174
Failure code [DHHBKA] Failure of HST Press Sens Circuit (MA) 1176
Failure code [DHHBKY] Hot Short of HST Press Sens Circuit (MA) 1178
Failure code [DHHCKA] Failure of HST Press Sens Circuit (MB) 1180
Failure code [DHHCKY] Hot Short of HST Press Sens Circuit (MB) 1182
Failure code [DHPCKA] Failure of Boom Press Sensor (Bottom) 1184
Failure code [DHPCKY] Hot Short of Boom Press Sensor (Bottom) 1186
Failure code [DHPEKA] Failure of Steering & Loader Pump Press 1188
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press 1190
Failure code [DHS8KA] Failure of Boom Raise PPC Sens Circuit 1192
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens Circuit 1194
Failure code [DHS9KA] Failure of Boom Lower PPC Sens Circuit 1196
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens Circuit 1198
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens Circuit 1200
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens Circuit 1202
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens Circuit 1204
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens Circuit 1206
Failure code [DHT8ZG] Steering Oil Pressure Low 1208
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit 1209
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 1211
Failure code [DK55KA] Failure of FNR Lever Potentio 1213
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit 1216
Failure code [DK55L5] Failure of FNR Lever Potentio 1218
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) 1219
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) 1222
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree 1225
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) 1228
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) 1231
Failure code [DK70KA] Failure of inching sensor Circuit 1234
Failure code [DK70KY] Hot Short of inching sensor Circuit 1237
Failure code [DKA0KA] Failure of Boom Angle Sensor 1239
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit 1241
Failure code [DKA0L0] Boom Angle Sensor Dislocation 1243
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 1245
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 1247
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) 1248
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) 1250
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) 1252
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) 1255
Failure code [DPQ1KR] LIN Discon (Switch Panel) 1257
Failure code [DPQ2KR] LIN Discon (LED Unit) 1260
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 1263
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 1266
Failure code [DT22KB] Ground Fault of Work Equip Lock Indic 1268
Failure code [DV00KB] Ground Fault of Buzzer Output 1270
Failure code [DW26KA] Disconnection of Motor 2 Solenoid 1272
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid 1274
Failure code [DW26KY] Hot Short of Motor 2 Solenoid 1276
Failure code [DW4BKA] Disconnection of Parking Brake Valve 1278
Failure code [DW4BKB] Ground Fault of Parking Brake Valve 1280
Failure code [DW4BKY] Hot Short of Parking Brake Valve 1282
Failure code [DW4RKA] Disconnection of Bucket EPC Sol (Tilt) 1283
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) 1285
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) 1287
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid 1288
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid 1290
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid 1292
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) 1293
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) 1295
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) 1297
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) 1299
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) 1301
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) 1303
Failure code [DX19KA] Disconnection of Motor 1 Solenoid 1304
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid 1306
Failure code [DX19KY] Hot Short of Motor 1 Solenoid 1308
Failure code [DX20KA] Disconnection of Clutch Control Solenoid 1310
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid 1312
Failure code [DX20KY] Hot Short of Clutch Control Solenoid 1314
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol 1316
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol 1318
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol 1320
Failure code [DXH7KA] Disconnection of Reverse Solenoid 1322
Failure code [DXH7KB] Ground Fault of Reverse Solenoid 1324
Failure code [DXH7KY] Hot Short of Reverse Solenoid 1326
Failure code [DXH8KA] Disconnection of Forward Solenoid 1328
Failure code [DXH8KB] Ground Fault of Forward Solenoid 1330
Failure code [DXH8KY] Hot Short of Forward Solenoid 1332
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) 1334
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 1336
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) 1338
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) 1339
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 1341
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) 1343
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal 1344
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal 1347
Failure code [J141N1] Steering Pump Over Run 1349
Failure code [LA00L3] Failure of Fan Reverse 1350
Failure code [M100N1] HST Pump Over Run 1351
Failure code [M400N1] HST Motor 1 Over Run 1352
Troubleshooting of electrical system (E-mode) 1353
E-1 Engine does not start 1353
E-2 Manual preheating system does not work 1360
E-3 Automatic preheating system does not work 1363
E-4 While preheating is working, preheating monitor does not light up 1365
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing 1367
E-6 LCD unit on machine monitor displays nothing 1370
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) 1372
E-8 LCD on machine monitor does not display properly 1374
E-9 Meter unit display on machine monitor is abnormal 1376
E-10 Night lighting lamp of meter unit on machine monitor is abnormal 1379
E-11 Caution LED on machine monitor is abnormal 1382
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly 1384
E-13 Two switches operation of switch panel on machine monitor does not function 1386
E-14 Switch panel buzzer of machine monitor is abnormal 1389
E-15 Rearview monitor does not light up or backlight flickers 1391
E-16 Rearview monitor images are not displayed clearly 1394
E-17 Rearview monitor brightness cannot be adjusted 1397
E-18 Night lighting lamp of rearview monitor is abnormal 1400
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly 1402
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position 1403
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light 1407
E-22 The HST oil filter clogging caution lamp does not light up 1409
E-23 Radiator coolant level caution lamp does not light 1411
E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light 1413
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 1414
E-26 Fuel level gauge does not indicate correct level 1416
E-27 Seat belt caution lamp indication is abnormal 1418
E-28 Horn does not sound 1419
E-29 Horn does not stop sounding 1422
E-30 Alarm buzzer does not sound 1424
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding 1426
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 1427
E-33 Setting does not change while operating traction control switch 1429
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 1431
E-35 Remote positioner does not work or cannot be released 1434
E-36 Bucket positioner does not work or cannot be released 1436
E-37 Direction selector (FNR) switch mode is not selected or not released 1439
E-38 PZ auto tilt-in does not work 1441
E-39 Tracktion level does not display MAX when max traction switch is turned ON 1444
E-40 ECSS function cannot be selected or cannot be released 1446
E-41 None of headlamp, clearance lamp, and tail lamp lights 1448
E-42 Clearance lamp, tail lamp and license-plate lamp do not light up or go out 1450
E-43 Both High and Low beams of headlamp do not light up or go out 1454
E-44 Low beam of headlamp does not light up or go out 1458
E-45 High beam of headlamp does not light up or go out 1460
E-46 Front working lamp does not light up or go out 1462
E-47 Rear working lamp does not light up or go out 1466
E-48 All of turn signal lamps and hazard lamps do not flash or go out 1470
E-49 Turn signal lamps do not flash or go out 1473
E-50 Hazard lamp does not flash or go out 1476
E-51 Brake lamp does not light or stays lighted 1479
E-52 Backup lamp does not light up or does not go out 1482
E-53 Backup buzzer does not sound or continues to sound 1485
E-54 Front wiper does not operate 1487
E-55 Rear wiper does not operate 1490
E-56 Window washer does not operate 1492
E-57 KOMTRAX system does not operate normally 1495
Troubleshooting of hydraulic and mechanical system (H-mode) 1497
Information described in troubleshooting table (H-mode) 1497
System chart of hydraulic and mechanical systems 1498
Failure mode and cause table 1500
H-1 Machine does not travel forward or backward 1506
H-2 Machine does not travel forward (Machine travels backward normally) 1509
H-3 Machine does not travel backward (Machine travels forward normally) 1510
H-4 Machine does not travel forward or backward fast 1511
H-5 Machine does not travel forward fast (Machine travel backward fast) 1515
H-6 Machine does not travel backward fast (Machine travel forward fast) 1516
H-7 Machine lacks power neither when traveling forward nor backward 1517
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) 1520
H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) 1521
H-10 Engine stalls during travel or engine speed drops significantly 1522
H-11 Steering wheel is too heavy to turn 1523
H-12 Steering wheel is heavy to turn 1525
H-13 Machine sways or large shocks are made while machine turns 1526
H-14 Machine unintentionally turns when machine travels 1527
H-15 Wheel brakes do not work or are weak 1528
H-16 Wheel brakes are not released or drag 1529
H-17 Parking brake does not work or it is weak 1530
H-18 Parking brake is not released or drags 1531
H-19 Boom does not rise 1532
H-20 Boom moves slow or boom lacks lifting force 1534
H-21 Rising boom slows down at certain height 1536
H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground) 1537
H-23 Hydraulic drift of boom is large 1538
H-24 Boom moves up and down during operation 1539
H-25 Bucket does not tilt back 1540
H-26 Bucket moves slow or lacks tilt-back force 1542
H-27 Bucket decelerates during tilt-back operation 1544
H-28 Bucket cylinder does not hold bucket on ground 1545
H-29 Hydraulic drift of bucket is large 1546
H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) 1547
H-31 Boom and bucket control levers do not move smoothly and are heavy to move 1548
H-32 Operating work equipment causes engine speed to lower significantly or engine to stall 1549
H-33 Large shocks are made when work equipment starts to move and stops 1550
H-34 When certain work equipment is relieved hydraulically, other work equipment moves 1551
H-35 E C S S (travel damper) does not work and machine pitches and bounces 1552
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) 1553
H-37 Unusual noise is heard from around fan 1555
Troubleshooting of engine (S-mode) 1556
Information described in troubleshooting table (S mode) 1556
S-1 Engine does not crank when starting switch is turned to START position 1557
S-2 Engine cranks but no exhaust smoke comes out 1558
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1559
S-4 Engine startability is poor 1560
S-5 Engine does not pick up smoothly 1562
S-6 Engine stops during operation 1564
S-7 Engine runs rough or is unstable 1566
S-8 Engine lacks power 1567
S-9 KDPF gets clogged in a short time 1569
S-10 Engine oil consumption is excessive 1571
S-11 Engine oil becomes contaminated early 1572
S-12 Fuel consumption is excessive 1573
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1574
S-14 Oil pressure drops 1575
S-15 Fuel mixes into engine oil 1576
S-16 Water mixes into engine oil (milky) 1577
S-17 Coolant temperature rises too high (overheating) 1578
S-18 Unusual noise is heard 1579
S-19 Vibration is excessive 1580
S-20 Air cannot be bled from fuel circuit 1582
S-21 Active regeneration is executed frequently 1583
S-22 Active regeneration takes time 1584
S-23 White smoke is exhausted during active regeneration 1585
50 Disassembly and assembly 1587
Table of contents 1588
Related information on disassembly and assembly 1590
How to read this manual 1590
Coating materials list 1592
Special tools list 1596
Sketches of special tools 1603
Engine and cooling system 1619
Removal and installation of supply pump assembly 1619
Removal and installation of injector assembly 1623
Removal and installation of cylinder head assembly 1632
Removal and installation of engine hood assembly 1639
Removal and installation of grille assembly 1642
Removal and installation of radiator core assembly 1644
Removal and installation of aftercooler 1647
Removal and installation of hydraulic oil cooler 1649
Removal and installation of engine assembly 1650
Removal and installation of engine front oil seal 1656
Removal and installation of engine rear oil seal 1659
Removal and installation of cooling fan and fan motor assembly 1662
Removal and installation of KDPF assembly 1664
Disassembly and assembly of KDPF assembly 1668
Removal and installation of KCCV assembly 1677
Removal and installation of air cleaner assembly 1678
Removal and installation of KVGT assembly 1680
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1684
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 1686
Removal and installation of alternator belt 1689
Removal and installation of fuel tank assembly 1691
Power train 1694
Removal and installation of transfer assembly 1694
Disassembly and assembly of transfer assembly 1699
Disassembly and assembly of parking brake assembly 1731
Disassembly and assembly of differential assembly 1739
Removal and installation of front axle assembly 1763
Removal and installation of rear axle assembly 1765
Disassembly and assembly of axle housing assembly 1768
Undercarriage and frame 1777
Removal and installation of center hinge pin 1777
Removal and installation of counterweight assembly 1786
Hydraulic system 1788
Removal and installation of hydraulic tank assembly 1788
Removal and installation of control valve assembly 1791
Disassembly and assembly of control valve assembly 1795
Removal and installation of hydraulic pump assembly 1798
Removal and installation of HST motor1 assembly 1802
Removal and installation of HST motor2 assembly 1804
Disassembly and assembly of hydraulic cylinder assembly 1806
Work equipment 1813
Removal and installation of work equipment assembly 1813
Cab and its attachments 1819
Removal and installation of operator’s cab and floor frame assembly 1819
Removal and installation of operator’s cab glass (adhered glass) 1824
Removal and installation of operator’s seat assembly 1832
Removal and installation of seat belt 1834
Electrical system 1835
Removal and installation of machine monitor assembly 1835
Removal and installation of engine controller assembly 1837
Removal and installation of HST controller assembly 1839
Removal and installation of air conditioner controller assembly 1841
Removal and installation of monitor controller assembly 1842
Removal and installation of mass air flow and temperature sensor 1844
Removal and installation of KOMTRAX terminal assembly 1845
Air conditioner unit 1846
Removal and installation of air conditioner compressor 1846
Removal and installation of air conditioner condenser 1848
Removal and installation of air conditioner unit assembly 1850
60 Maintenance standard 1855
Table of contents 1856
Engine and cooling system 1857
Engine related parts 1857
Cooling fan motor 1858
Power train 1860
Damper 1860
Transfer 1861
Drive shaft 1868
Axle 1869
Differential 1871
Limited slip differential 1875
Final drive 1877
Steering system 1881
Steering column 1881
Priority valve 1882
Emergency steering valve 1883
Steering cylinder 1884
Brake system 1886
Brake accumulator charge valve 1886
Slack adjuster 1887
Brake 1888
Parking brake 1890
Parking brake solenoid valve 1891
Undercarriage and frame 1892
Axle mount 1892
Center hinge pin 1894
Hydraulic system 1898
Hydraulic tank 1898
Double type gear pump 1899
Steering and work equipment pump 1900
Control valve 1904
Self-pressure reducing valve 1917
Work equipment PPC valve 1919
Work equipment lock solenoid valve 1921
Work equipment 1922
Work equipment linkage 1922
Bucket 1926
Work equipment cylinder 1928
Cab and its attachments 1929
Cab mount 1929
Electrical system 1930
Bucket positioner 1930
Fork positioner 1931
Remote boom positioner 1932
80 Appendix 1933
Table of contents 1934
Air conditioner components 1935
Precautions for refrigerant 1935
Air conditioner component 1936
Configuration and function of refrigeration cycle 1938
Outline of refrigeration cycle 1939
Air conditioner unit 1941
Dual pressure switch 1946
Air conditioner controller 1947
Compressor 1948
Condenser 1949
Receiver drier 1950
Sunlight sensor 1952
Outer temperature sensor (outside air temperature sensor) 1953
Procedure for testing and troubleshooting 1954
Circuit diagram and arrangement of connector pins 1956
System diagram 1959
Parts and connectors layout 1962
Testing with self-diagnosis function 1967
How to open the electrical system abnormality record screen in service mode of the machine monitor 1968
Testing temperature control system 1970
Testing vent (mode) changeover 1972
Testing FRESH/RECIRC air changeover 1974
Testing evaporator temperature sensor 1976
Testing relays 1978
Troubleshooting chart 1 1980
Troubleshooting chart 2 1981
Information in troubleshooting table 1983
Failure code list related to air conditioner 1984
Failure code [879AKA] A/C Inner Sensor Open Circuit 1985
Failure code [879AKB] A/C Inner Sensor Short Circuit 1987
Failure code [879BKA] A/C Outer Sensor Open Circuit 1989
Failure code [879BKB] A/C Outer Sensor Short Circuit 1991
Failure code [879CKA] Ventilating Sensor Open Circuit 1993
Failure code [879CKB] Ventilating Sensor Short Circuit 1995
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 1997
Failure code [879EMC] Ventilation Damper Abnormality 1999
Failure code [879FMC] Air Mix Damper Abnormality 2002
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 2005
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 2008
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2011
A-4 Troubleshooting for FRESH/RECIRC air changeover 2014
Troubleshooting with gauge pressure 2016
Connection of service tool 2019
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 2021
Handling of compressor oil 2023
90 Diagrams and drawings 2025
Table of contents 2026
Hydraulic circuit diagram 2027
Symbols in hydraulic circuit diagram 2027
Hydraulic circuit diagram 2031
Electric circuit diagram 2032
Symbols in electric circuit diagram 2032
Electrical circuit diagram of machine body 2036
Electrical circuit diagram of floor 2040
INDEX 2048

DESCRIPTION:

Komatsu WA270-7 WHEEL LOADER Shop Manual CEBM027601 –  PDF DOWNLOAD

• SERIAL NUMBERS WA270-7 A27001 and up

Composition of shop manual:
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

G.B 20/12/24