Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu WA270-7 Wheel Loader Shop Manual SEN06255-01 – PDF DOWNLOAD
Original price was: $59.95.$35.95Current price is: $35.95.
Komatsu WA270-7 Wheel Loader Shop Manual
SERIAL NUMBERS 80001 and up
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu WA270-7 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA270-7 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA270-7
Serial Number: 80001 and up
Book Code: SEN06255-01
Language: English
Pages: 2047
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA270-7 Wheel Loader Shop Manual
How to read the shop manual:
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.
TABLE OF CONTENTS:
Komatsu WA270-7 Wheel Loader Shop Manual
Cover............................................................................................................................................................................................. 1 00 Index and foreword ............................................................................................................................................................................ 3 Index ........................................................................................................................................................................................ 4 Foreword, safety and general information ..................................................................................................................................................... 19 Important safety notice .................................................................................................................................................................. 19 How to read the shop manual .............................................................................................................................................................. 26 Explanation of terms for maintenance standard ............................................................................................................................................ 28 Handling equipment of fuel system devices ................................................................................................................................................ 30 Handling of intake system parts .......................................................................................................................................................... 31 Handling of hydraulic equipment .......................................................................................................................................................... 32 Method of disconnecting and connecting of push-pull type coupler ......................................................................................................................... 34 Handling of electrical equipment ......................................................................................................................................................... 37 How to read electric wire code ........................................................................................................................................................... 45 Precautions when performing operation .................................................................................................................................................... 48 Practical use of KOMTRAX ................................................................................................................................................................. 53 Standard tightening torque table ......................................................................................................................................................... 54 List of abbreviation ..................................................................................................................................................................... 60 Conversion table ......................................................................................................................................................................... 65 01 Specification ................................................................................................................................................................................. 71 Table of contents ............................................................................................................................................................................ 72 Specifications ............................................................................................................................................................................... 73 Specification drawing .................................................................................................................................................................... 73 Specifications ........................................................................................................................................................................... 75 Weight table ............................................................................................................................................................................. 80 Table of fuel, coolant, and lubricants ................................................................................................................................................... 82 10 Structure and function ........................................................................................................................................................................ 83 Table of contents ............................................................................................................................................................................ 84 Engine and cooling system .................................................................................................................................................................... 86 Engine related parts ..................................................................................................................................................................... 86 KVGT ..................................................................................................................................................................................... 88 EGR system piping drawing ................................................................................................................................................................ 95 EGR system circuit diagram ............................................................................................................................................................... 97 EGR valve ................................................................................................................................................................................ 99 EGR cooler ............................................................................................................................................................................... 101 KCCV layout drawing ...................................................................................................................................................................... 102 KCCV ventilator .......................................................................................................................................................................... 104 KDPF ..................................................................................................................................................................................... 106 Cooling system ........................................................................................................................................................................... 110 Cooling fan motor ........................................................................................................................................................................ 112 Power train .................................................................................................................................................................................. 122 Power train system ....................................................................................................................................................................... 122 Layout of power train parts .............................................................................................................................................................. 124 Damper ................................................................................................................................................................................... 125 HST pump ................................................................................................................................................................................. 126 HST motor1 ............................................................................................................................................................................... 139 HST motor2 ............................................................................................................................................................................... 141 Transfer ................................................................................................................................................................................. 146 Clutch solenoid valve .................................................................................................................................................................... 153 Drive shaft .............................................................................................................................................................................. 155 Axle ..................................................................................................................................................................................... 156 Differential ............................................................................................................................................................................. 158 Torque proportional differential ......................................................................................................................................................... 162 Limited slip differential ................................................................................................................................................................ 164 Final drive .............................................................................................................................................................................. 169 Steering system .............................................................................................................................................................................. 172 Layout of steering devices ............................................................................................................................................................... 172 Steering column .......................................................................................................................................................................... 173 Priority valve ........................................................................................................................................................................... 174 Cushion valve ............................................................................................................................................................................ 178 Emergency steering valve ................................................................................................................................................................. 179 Orbitrol valve ........................................................................................................................................................................... 182 2way restrictor valve .................................................................................................................................................................... 188 Brake system ................................................................................................................................................................................. 189 Layout of brake parts .................................................................................................................................................................... 189 Brake accumulator charge valve ........................................................................................................................................................... 191 Brake valve .............................................................................................................................................................................. 196 Brake accumulator ........................................................................................................................................................................ 200 Slack adjuster ........................................................................................................................................................................... 201 Brake .................................................................................................................................................................................... 203 Parking brake control .................................................................................................................................................................... 206 Parking brake ............................................................................................................................................................................ 207 Parking brake solenoid valve ............................................................................................................................................................. 208 Undercarriage and frame ...................................................................................................................................................................... 210 Axle mount ............................................................................................................................................................................... 210 Center hinge pin ......................................................................................................................................................................... 212 Tire ..................................................................................................................................................................................... 213 Hydraulic system ............................................................................................................................................................................. 215 Hydraulic component layout ............................................................................................................................................................... 215 Work equipment control ................................................................................................................................................................... 217 Hydraulic tank ........................................................................................................................................................................... 218 Double type gear pump .................................................................................................................................................................... 221 Steering and work equipment pump ......................................................................................................................................................... 222 Control valve ............................................................................................................................................................................ 234 CLSS ..................................................................................................................................................................................... 244 Hydraulic circuit diagram and names of valves ............................................................................................................................................ 248 Self-pressure reducing valve ............................................................................................................................................................. 261 Work equipment PPC valve ................................................................................................................................................................. 266 Work equipment lock solenoid valve ....................................................................................................................................................... 274 PPC circuit accumulator .................................................................................................................................................................. 275 ECSS accumulator ......................................................................................................................................................................... 276 Work equipment ............................................................................................................................................................................... 277 Work equipment linkage ................................................................................................................................................................... 277 Bucket ................................................................................................................................................................................... 278 Cab and its attachments ...................................................................................................................................................................... 279 ROPS cab ................................................................................................................................................................................. 279 Cab mount ................................................................................................................................................................................ 281 Electrical system ............................................................................................................................................................................ 282 Engine control system .................................................................................................................................................................... 282 Preheating system ........................................................................................................................................................................ 285 Engine output limit function ............................................................................................................................................................. 287 Automatic warm-up function ............................................................................................................................................................... 288 Parking brake control system ............................................................................................................................................................. 289 System operating lamp function ........................................................................................................................................................... 293 Battery disconnect switch function ....................................................................................................................................................... 294 HST controller system .................................................................................................................................................................... 296 Machine monitor system ................................................................................................................................................................... 336 Rearview monitor system .................................................................................................................................................................. 357 KOMTRAX system ........................................................................................................................................................................... 360 System component parts ................................................................................................................................................................... 363 Sensor ................................................................................................................................................................................... 386 20 Standard value tables ......................................................................................................................................................................... 407 Table of contents ............................................................................................................................................................................ 408 Standard service value table ................................................................................................................................................................. 409 Standard value table for engine .......................................................................................................................................................... 409 Standard value table for machine ......................................................................................................................................................... 411 Standard value table for electrical system ............................................................................................................................................... 423 30 Testing and adjusting ......................................................................................................................................................................... 433 Table of contents ............................................................................................................................................................................ 434 Related information on testing and adjusting ................................................................................................................................................. 436 Tools for testing and adjusting .......................................................................................................................................................... 436 Sketch of tools for testing and adjusting ................................................................................................................................................ 442 Engine and cooling system .................................................................................................................................................................... 443 Testing engine speed ..................................................................................................................................................................... 443 Testing boost pressure ................................................................................................................................................................... 444 Testing exhaust gas temperature .......................................................................................................................................................... 446 Testing exhaust gas color ................................................................................................................................................................ 447 Testing and adjusting valve clearance .................................................................................................................................................... 449 Testing compression pressure ............................................................................................................................................................. 451 Testing blowby pressure .................................................................................................................................................................. 455 Testing engine oil pressure .............................................................................................................................................................. 456 Testing EGR valve and KVGT driving oil pressure .......................................................................................................................................... 457 Testing fuel pressure .................................................................................................................................................................... 458 Testing fuel discharge, return and leakage ............................................................................................................................................... 462 Bleeding air from fuel system ............................................................................................................................................................ 467 Testing fuel circuit for leakage ......................................................................................................................................................... 469 Handling cylinder cutout mode operation .................................................................................................................................................. 470 Handling no-injection cranking operation ................................................................................................................................................. 471 Testing of KDPF and muffler stack for looseness and damage ............................................................................................................................... 472 Testing of installed condition of cylinder heads and manifolds ........................................................................................................................... 473 Testing engine piping for damage and looseness ........................................................................................................................................... 474 Testing and adjusting air conditioner compressor belt tension ............................................................................................................................ 475 Replacing alternator belt ................................................................................................................................................................ 476 Power train .................................................................................................................................................................................. 477 Testing oil leakage from axle final drive ................................................................................................................................................ 477 Testing drive shaft for looseness, backlash, and damage .................................................................................................................................. 478 Testing accelerator pedal ................................................................................................................................................................ 479 Testing and adjusting HST oil pressure ................................................................................................................................................... 480 Testing transfer clutch control pressure ................................................................................................................................................. 483 Steering system .............................................................................................................................................................................. 484 Testing directional lever ................................................................................................................................................................ 484 Testing steering wheel ................................................................................................................................................................... 485 Testing work equipment control lever ..................................................................................................................................................... 487 Testing and adjusting steering circuit oil pressure ...................................................................................................................................... 489 Bleeding air from steering cylinder circuit .............................................................................................................................................. 491 Brake system ................................................................................................................................................................................. 492 Testing brake pedal ...................................................................................................................................................................... 492 Testing braking performance .............................................................................................................................................................. 493 Testing and adjusting of accumulator charge pressure ..................................................................................................................................... 494 Testing wheel brake oil pressure ......................................................................................................................................................... 496 Testing lowering of wheel brake pressure ................................................................................................................................................. 497 Testing wear of wheel brake disc ......................................................................................................................................................... 499 Bleeding air from wheel brake circuit .................................................................................................................................................... 500 Releasing remaining pressure in brake accumulator circuit ................................................................................................................................ 501 Testing parking brake performance ........................................................................................................................................................ 502 Testing wear of parking brake disc ....................................................................................................................................................... 503 Testing parking brake release pressure ................................................................................................................................................... 504 Method of releasing parking brake manually ............................................................................................................................................... 505 Hydraulic system ............................................................................................................................................................................. 506 Testing cooling fan speed ................................................................................................................................................................ 506 Testing cooling fan pump circuit oil pressure ............................................................................................................................................ 507 Bleeding air from hydraulic fan circuit .................................................................................................................................................. 509 Testing and adjusting work equipment PPC oil pressure .................................................................................................................................... 510 Testing and adjusting work equipment oil pressure ........................................................................................................................................ 512 Bleeding air from work equipment circuit ................................................................................................................................................. 516 Releasing remaining pressure from work equipment circuit ................................................................................................................................. 517 Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas .................................................................................. 519 Work equipment ............................................................................................................................................................................... 523 Testing and adjusting bucket positioner and bucket proximity switch ...................................................................................................................... 523 Testing and adjusting boom position detection lever ...................................................................................................................................... 525 Electrical system ............................................................................................................................................................................ 526 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ................................................................................................... 526 Special functions of machine monitor ..................................................................................................................................................... 527 Adjusting rearview camera angle .......................................................................................................................................................... 605 Handling voltage circuit of engine controller ............................................................................................................................................ 606 Handling battery disconnect switch ....................................................................................................................................................... 607 Testing diodes ........................................................................................................................................................................... 608 Pm clinic .................................................................................................................................................................................... 609 Pm Clinic service ........................................................................................................................................................................ 609 Check sheet .............................................................................................................................................................................. 610 40 Troubleshooting ............................................................................................................................................................................... 615 Table of contents ............................................................................................................................................................................ 616 Related information on troubleshooting ....................................................................................................................................................... 625 Troubleshooting points ................................................................................................................................................................... 625 Sequence of events in troubleshooting .................................................................................................................................................... 627 Checks before troubleshooting ............................................................................................................................................................ 629 Inspection procedure before troubleshooting .............................................................................................................................................. 631 Preparation for troubleshooting of electrical system ..................................................................................................................................... 648 Classification and procedures for troubleshooting ........................................................................................................................................ 654 Symptom and troubleshooting numbers ...................................................................................................................................................... 657 Information described in troubleshooting table ........................................................................................................................................... 660 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit .................................................................................................. 662 Connector list and layout ................................................................................................................................................................ 665 Connector contact identification ......................................................................................................................................................... 679 T-branch box and T-branch adapter table .................................................................................................................................................. 717 Fuse location table ...................................................................................................................................................................... 722 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ............................................................................................................................ 725 Precautions when performing troubleshooting of machine monitor ........................................................................................................................... 728 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit .................................................................................................. 730 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .......................................................................................................... 735 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) .............................................................................................. 736 Failure codes table ...................................................................................................................................................................... 737 Troubleshooting by failure code (Display of code) ............................................................................................................................................ 749 Failure code [2F00MA] Failure of Parking Brake Circuit ................................................................................................................................... 749 Failure code [2F00MB] Malfunction of Parking Brake ....................................................................................................................................... 752 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................................................................................................... 754 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ................................................................................................................................ 756 Failure code [6091NX] HST Oil Filter Clogging ............................................................................................................................................ 758 Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ......................................................................................................................... 760 Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. .......................................................................................................................... 762 Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ............................................................................................................................. 764 Failure code [879AKA] A/C Inner Sensor Open Circuit ...................................................................................................................................... 766 Failure code [879AKB] A/C Inner Sensor Short Circuit ..................................................................................................................................... 767 Failure code [879BKA] A/C Outer Sensor Open Circuit ...................................................................................................................................... 768 Failure code [879BKB] A/C Outer Sensor Short Circuit ..................................................................................................................................... 769 Failure code [879CKA] Ventilating Sensor Open Circuit .................................................................................................................................... 770 Failure code [879CKB] Ventilating Sensor Short Circuit ................................................................................................................................... 771 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................................................................................................. 772 Failure code [879EMC] Ventilation Damper Abnormality ..................................................................................................................................... 773 Failure code [879FMC] Air Mix Damper Abnormality ......................................................................................................................................... 774 Failure code [989L00] Engine Controller Lock Caution 1 ................................................................................................................................... 775 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................................................................................... 776 Failure code [989N00] Engine Controller Lock Caution 3 ................................................................................................................................... 777 Failure code [A1U0N3] HC Desorb Request 1 ................................................................................................................................................ 778 Failure code [A1U0N4] HC Desorb Request 2 ................................................................................................................................................ 780 Failure code [B@BAZG] Eng Oil Press Low .................................................................................................................................................. 782 Failure code [B@BCNS] Eng Water Overheat ................................................................................................................................................. 783 Failure code [B@BCZK] Eng Water Level Low ................................................................................................................................................ 784 Failure code [B@CRNS] HST Oil Temp. Overheat ............................................................................................................................................. 786 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................................................................................................... 787 Failure code [CA122] Chg Air Press Sensor High Error ..................................................................................................................................... 788 Failure code [CA123] Chg Air Press Sensor Low Error ...................................................................................................................................... 790 Failure code [CA131] Throttle Sensor High Error .......................................................................................................................................... 792 Failure code [CA132] Throttle Sensor Low Error ........................................................................................................................................... 794 Failure code [CA144] Coolant Temp Sens High Error ........................................................................................................................................ 796 Failure code [CA145] Coolant Temp Sens Low Error ......................................................................................................................................... 798 Failure code [CA153] Chg Air Temp Sensor High Error ...................................................................................................................................... 800 Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................................................................................................... 802 Failure code [CA187] Sensor 2 Supply Volt Low Error ...................................................................................................................................... 804 Failure code [CA221] Ambient Press Sensor High Error ..................................................................................................................................... 806 Failure code [CA222] Ambient Press Sensor Low Error ...................................................................................................................................... 808 Failure code [CA227] Sensor 2 Supply Volt High Error ..................................................................................................................................... 810 Failure code [CA234] Eng Overspeed ....................................................................................................................................................... 811 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................................................................................................... 812 Failure code [CA239] Ne Speed Sens Supply Volt High Error ................................................................................................................................ 813 Failure code [CA271] IMV/PCV1 Short Error ................................................................................................................................................ 814 Failure code [CA272] IMV/PCV1 Open Error ................................................................................................................................................. 816 Failure code [CA295] Ambient Press Sens In Range Error ................................................................................................................................... 818 Failure code [CA322] Inj #1(L#1) Open/Short Error ........................................................................................................................................ 819 Failure code [CA323] Inj #5(L#5) Open/Short Error ........................................................................................................................................ 821 Failure code [CA324] Inj #3(L#3) Open/Short Error ........................................................................................................................................ 823 Failure code [CA325] Inj #6(L#6) Open/Short Error ........................................................................................................................................ 825 Failure code [CA331] Inj #2(L#2) Open/Short Error ........................................................................................................................................ 827 Failure code [CA332] Inj #4(L#4) Open/Short Error ........................................................................................................................................ 829 Failure code [CA343] ECM Critical Internal Failure ....................................................................................................................................... 831 Failure code [CA351] Injectors Drive Circuit Error ....................................................................................................................................... 832 Failure code [CA352] Sensor 1 Supply Volt Low Error ...................................................................................................................................... 833 Failure code [CA356] Mass Air Flow Sensor High Error ..................................................................................................................................... 835 Failure code [CA357] Mass Air Flow Sensor Low Error ...................................................................................................................................... 837 Failure code [CA386] Sensor 1 Supply Volt High Error ..................................................................................................................................... 839 Failure code [CA428] Water in Fuel Sensor High Error ..................................................................................................................................... 840 Failure code [CA429] Water in Fuel Sensor Low Error ...................................................................................................................................... 842 Failure code [CA431] Idle Validation Sw Error ............................................................................................................................................ 844 Failure code [CA432] Idle Validation Process Error ....................................................................................................................................... 847 Failure code [CA435] Eng Oil Press Sw Error .............................................................................................................................................. 850 Failure code [CA441] Battery Voltage Low Error ........................................................................................................................................... 851 Failure code [CA442] Battery Voltage High Error .......................................................................................................................................... 853 Failure code [CA449] Rail Press Very High Error .......................................................................................................................................... 854 Failure code [CA451] Rail Press Sensor High Error ........................................................................................................................................ 855 Failure code [CA452] Rail Press Sensor Low Error ......................................................................................................................................... 857 Failure code [CA488] Chg Air Temp High Torque Derate ..................................................................................................................................... 859 Failure code [CA515] Rail Press Sens Sup Volt High Error ................................................................................................................................. 860 Failure code [CA516] Rail Press Sens Sup Volt Low Error .................................................................................................................................. 862 Failure code [CA553] Rail Press High Error ............................................................................................................................................... 864 Failure code [CA555] Crankcase Press High Error 1 ........................................................................................................................................ 865 Failure code [CA556] Crankcase Press High Error 2 ........................................................................................................................................ 866 Failure code [CA559] Rail Press Low Error ................................................................................................................................................ 867 Failure code [CA595] Turbo Speed High Error 2 ............................................................................................................................................ 869 Failure code [CA687] Turbo Speed Low Error ............................................................................................................................................... 870 Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................................................................................... 872 Failure code [CA691] Intake Air Temp Sens High Error ..................................................................................................................................... 874 Failure code [CA692] Intake Air Temp Sens Low Error ...................................................................................................................................... 876 Failure code [CA697] ECM Internal Temp Sensor High Error ................................................................................................................................. 878 Failure code [CA698] ECM Int Temp Sensor Low Error ....................................................................................................................................... 879 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..................................................................................................................................... 880 Failure code [CA778] Eng Bkup Speed Sensor Error ......................................................................................................................................... 882 Failure code [CA1117] Persistent Data Lost Error ......................................................................................................................................... 887 Failure code [CA1664] KDOC Malfunction ................................................................................................................................................... 888 Failure code [CA1691] Regeneration Ineffective ........................................................................................................................................... 891 Failure code [CA1695] Sensor 5 Supply Volt High Error .................................................................................................................................... 894 Failure code [CA1696] Sensor 5 Supply Volt Low Error ..................................................................................................................................... 895 Failure code [CA1843] Crankcase Press Sens High Error .................................................................................................................................... 897 Failure code [CA1844] Crankcase Press Sens Low Error ..................................................................................................................................... 899 Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................................................................................................... 901 Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................................................................................................... 903 Failure code [CA1883] KDPF Delta P Sens In Range Error ................................................................................................................................... 905 Failure code [CA1921] KDPF Soot Load High Error 1 ........................................................................................................................................ 909 Failure code [CA1922] KDPF Soot Load High Error 2 ........................................................................................................................................ 912 Failure code [CA1942] Crankcase Press Sens In Range Error ................................................................................................................................ 917 Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................................................................................................... 918 Failure code [CA2185] Throt Sensor Sup Volt High Error ................................................................................................................................... 921 Failure code [CA2186] Throt Sensor Sup Volt Low Error .................................................................................................................................... 923 Failure code [CA2249] Rail Press Very Low Error .......................................................................................................................................... 925 Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................................................................................................... 926 Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................................................................................................... 928 Failure code [CA2288] Turbo Speed High Error 1 ........................................................................................................................................... 931 Failure code [CA2311] IMV Solenoid Error ................................................................................................................................................. 932 Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................................................................................................... 933 Failure code [CA2353] EGR Valve Solenoid Short Error ..................................................................................................................................... 935 Failure code [CA2357] EGR Valve Servo Error .............................................................................................................................................. 937 Failure code [CA2373] Exhaust Manifold Press Sens High error ............................................................................................................................. 938 Failure code [CA2374] Exhaust Manifold Press Sens Low error .............................................................................................................................. 940 Failure code [CA2375] EGR Orifice Temp Sens High Error ................................................................................................................................... 942 Failure code [CA2376] EGR Orifice Temp Sens Low Error .................................................................................................................................... 944 Failure code [CA2381] KVGT Pos Sens High Error ........................................................................................................................................... 946 Failure code [CA2382] KVGT Pos Sens Low Error ............................................................................................................................................ 948 Failure code [CA2383] KVGT Solenoid Open Error ........................................................................................................................................... 951 Failure code [CA2386] KVGT Solenoid Short Error .......................................................................................................................................... 953 Failure code [CA2387] KVGT Servo Error ................................................................................................................................................... 955 Failure code [CA2554] Exh Manifold Press Sens In Range Error ............................................................................................................................. 956 Failure code [CA2555] Grid Htr Relay Volt Low Error ...................................................................................................................................... 957 Failure code [CA2556] Grid Htr Relay Volt High Error ..................................................................................................................................... 959 Failure code [CA2637] KDOC Face Plugging ................................................................................................................................................. 961 Failure code [CA2639] Manual Stationary Regeneration Request ............................................................................................................................. 963 Failure code [CA2961] EGR Orifice Temp High Error 1 ...................................................................................................................................... 966 Failure code [CA2973] Chg Air Press Sensor In Range Error ................................................................................................................................ 967 Failure code [CA3133] KDPF Outlet Press Sens High Error .................................................................................................................................. 968 Failure code [CA3134] KDPF Outlet Press Sens Low Error ................................................................................................................................... 970 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .............................................................................................................................. 972 Failure code [CA3251] KDOC Inlet Temp High Error ......................................................................................................................................... 976 Failure code [CA3253] KDOC Temp Error - Non Regeneration ................................................................................................................................. 979 Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................................................................................................... 982 Failure code [CA3255] KDPF Temp Error - Non Regeneration ................................................................................................................................. 985 Failure code [CA3256] KDPF Outlet Temp High Error 1 ...................................................................................................................................... 988 Failure code [CA3311] KDOC Outlet Temp High Error 2 ...................................................................................................................................... 991 Failure code [CA3312] KDPF Outlet Temp High Error 2 ...................................................................................................................................... 994 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................................................................................................... 997 Failure code [CA3314] KDOC Inlet Temp Sens High Error ....................................................................................................................................1000 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ................................................................................................................................1003 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....................................................................................................................................1007 Failure code [CA3317] KDOC Outlet Temp Sens High Error ...................................................................................................................................1010 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...............................................................................................................................1013 Failure code [CA3319] KDPF Outlet Temp Sens High Error ...................................................................................................................................1017 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....................................................................................................................................1020 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...............................................................................................................................1023 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...........................................................................................................................1027 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ............................................................................................................................1029 Failure code [CA3741] Rail Press Valve Trip Error ........................................................................................................................................1031 Failure code [D110L4] Disconnection of Battery Relay Signal ..............................................................................................................................1032 Failure code [D160KA] Disconnection of Backup Lamp Relay Output ..........................................................................................................................1034 Failure code [D160KY] Hot Short of Backup Lamp Relay Output ..............................................................................................................................1036 Failure code [D191KA] Disconnection of Neutral Output Relay ..............................................................................................................................1038 Failure code [D191KB] Ground Fault of Neutral Output Relay ...............................................................................................................................1040 Failure code [D191KY] Hot Short of Neutral Output Relay ..................................................................................................................................1042 Failure code [D192KA] Disconnection of ECSS Solenoid .....................................................................................................................................1044 Failure code [D192KB] Ground Fault of ECSS Solenoid ......................................................................................................................................1046 Failure code [D192KY] Hot Short of ECSS Solenoid .........................................................................................................................................1047 Failure code [D19JKZ] Personal Code Relay Abnormality ....................................................................................................................................1048 Failure code [D1B0KA] Disconnection of HST Safety Relay ..................................................................................................................................1050 Failure code [D1B0KB] Ground Fault of HST Safety Relay ...................................................................................................................................1052 Failure code [D1B0KY] Hot Short of HST Safety Relay ......................................................................................................................................1054 Failure code [D1B0MC] Malfunction of HST Safety Relay ....................................................................................................................................1056 Failure code [D1E6KA] Disconnection of Parking Brake Relay ...............................................................................................................................1057 Failure code [D1E6KB] Ground Fault of Parking Brake Relay ................................................................................................................................1059 Failure code [D1E6KY] Hot Short of Parking Brake Relay ...................................................................................................................................1061 Failure code [D5ZHKA] Failure of Key SW C Signal .........................................................................................................................................1063 Failure code [D5ZHKB] Key SW C Signal Short Circuit ......................................................................................................................................1065 Failure code [D5ZHL6] Disconnection of Key SW C ..........................................................................................................................................1067 Failure code [D811MC] KOMTRAX Error ......................................................................................................................................................1068 Failure code [D862KA] GPS Antenna Open Circuit ...........................................................................................................................................1069 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ..............................................................................................................................1070 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .............................................................................................................................1072 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ............................................................................................................................................1074 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..............................................................................................................................................1075 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...........................................................................................................................1077 Failure code [DAF0MB] Monitor ROM Abnormality ............................................................................................................................................1078 Failure code [DAF0MC] Monitor Error ......................................................................................................................................................1079 Failure code [DAF3KK] Controller Power Source Low (MON) ..................................................................................................................................1080 Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................................................................................................1082 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .............................................................................................................................1083 Failure code [DAFGMC] GPS Module Error ...................................................................................................................................................1084 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ..................................................................................................................................1085 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) .................................................................................................................................1087 Failure code [DAFQKR] CAN2 Discon (Monitor) ..............................................................................................................................................1089 Failure code [DAJ0KK] Controller Power Source Low (HST) ..................................................................................................................................1090 Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ...........................................................................................................................1093 Failure code [DAJ0MC] HST Con Error ......................................................................................................................................................1094 Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ..................................................................................................................................1095 Failure code [DAJ2KK] Solenoid Power Source Low (HST) ....................................................................................................................................1097 Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ............................................................................................................................1100 Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay .................................................................................................................................1102 Failure code [DAJ5KX] Failure of 5V Power Source 0 .......................................................................................................................................1104 Failure code [DAJ6KX] Failure of 5V Power Source 1 .......................................................................................................................................1106 Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) .............................................................................................................................1108 Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ..................................................................................................................................1109 Failure code [DAJLKB] Operating Lamp Short Circuit (HST) .................................................................................................................................1111 Failure code [DAJQKR] CAN2 Discon ( HST Con) .............................................................................................................................................1113 Failure code [DAJRKR] CAN1 Discon ( HST Con) .............................................................................................................................................1114 Failure code [DAJRMA] Inconsistency of Option Selection (HST) ............................................................................................................................1115 Failure code [DAZ9KQ] A/C Model Selection Abnormality ....................................................................................................................................1116 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...........................................................................................................................................1117 Failure code [DB2QKR] CAN2 Discon (Engine Con) ...........................................................................................................................................1118 Failure code [DB2RKR] CAN1 Discon (Engine Con) ...........................................................................................................................................1123 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...........................................................................................................................1127 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch .........................................................................................................................1129 Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ................................................................................................................................1131 Failure code [DDB6L4] Parking Brake Signal Malfunction ...................................................................................................................................1133 Failure code [DDD7KA] Failure of Variable Speed Control ..................................................................................................................................1136 Failure code [DDD7KY] Hot Short of Variable Speed Control ................................................................................................................................1138 Failure code [DDK3KA] FNR SW Input Signal Disconnection ..................................................................................................................................1140 Failure code [DDK3KB] FNR SW Input Signal Short Circuit ..................................................................................................................................1142 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...............................................................................................................................1144 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...............................................................................................................................1147 Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ............................................................................................................................1149 Failure code [DF10KA] Disconnection of Speed Range Input .................................................................................................................................1151 Failure code [DF10KB] Ground Fault of Speed Range Input ..................................................................................................................................1154 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor .............................................................................................................................1157 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ..................................................................................................................................1159 Failure code [DHG1KX] Out of Range of HST Oil Temp. Sensor ...............................................................................................................................1161 Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ...........................................................................................................................1163 Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) .........................................................................................................................1165 Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ...........................................................................................................................1167 Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) .........................................................................................................................1169 Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) .............................................................................................................................1171 Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ...........................................................................................................................1173 Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ...........................................................................................................................1175 Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. .........................................................................................................................1177 Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ............................................................................................................................1179 Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ..........................................................................................................................1181 Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ............................................................................................................................1183 Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ..........................................................................................................................1185 Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ...........................................................................................................................1187 Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit .........................................................................................................................1189 Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ...........................................................................................................................1191 Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit .........................................................................................................................1193 Failure code [DHT8ZG] Steering Oil Pressure Low ..........................................................................................................................................1195 Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ...........................................................................................................................1196 Failure code [DJF1KA] Disconnection of Fuel Level Sensor .................................................................................................................................1198 Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................................................................................................1200 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ............................................................................................................................1203 Failure code [DK55L5] Failure of FNR Lever Potentio ......................................................................................................................................1205 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...............................................................................................................................1206 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) .............................................................................................................................1209 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...........................................................................................................................1212 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ................................................................................................................................1215 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ..............................................................................................................................1218 Failure code [DK70KA] Failure of inching sensor Circuit ..................................................................................................................................1221 Failure code [DK70KY] Hot Short of inching sensor Circuit ................................................................................................................................1224 Failure code [DKA0KA] Failure of Boom Angle Sensor .......................................................................................................................................1226 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .............................................................................................................................1228 Failure code [DKA0L0] Boom Angle Sensor Dislocation ......................................................................................................................................1230 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor .........................................................................................................................1232 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...............................................................................................................................1234 Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ...........................................................................................................................1236 Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ...........................................................................................................................1238 Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ...............................................................................................................................1240 Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ..............................................................................................................................1243 Failure code [DPQ1KR] LIN Discon (Switch Panel) ..........................................................................................................................................1245 Failure code [DPQ2KR] LIN Discon (LED Unit) ..............................................................................................................................................1248 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) .....................................................................................................................................1251 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...........................................................................................................................................1254 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ............................................................................................................................1256 Failure code [DV00KB] Ground Fault of Buzzer Output ......................................................................................................................................1258 Failure code [DW26KA] Disconnection of Motor 2 Solenoid ..................................................................................................................................1260 Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ...................................................................................................................................1262 Failure code [DW26KY] Hot Short of Motor 2 Solenoid ......................................................................................................................................1264 Failure code [DW4BKA] Disconnection of Parking Brake Valve ...............................................................................................................................1266 Failure code [DW4BKB] Ground Fault of Parking Brake Valve ................................................................................................................................1268 Failure code [DW4BKY] Hot Short of Parking Brake Valve ...................................................................................................................................1270 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ............................................................................................................................1271 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .........................................................................................................................1273 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ............................................................................................................................1275 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid .............................................................................................................................1276 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ..............................................................................................................................1278 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid .................................................................................................................................1280 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ............................................................................................................................1281 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) .............................................................................................................................1283 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ................................................................................................................................1285 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..........................................................................................................................1287 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...........................................................................................................................1289 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ..............................................................................................................................1291 Failure code [DX19KA] Disconnection of Motor 1 Solenoid ..................................................................................................................................1292 Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ...................................................................................................................................1294 Failure code [DX19KY] Hot Short of Motor 1 Solenoid ......................................................................................................................................1296 Failure code [DX20KA] Disconnection of Clutch Control Solenoid ...........................................................................................................................1298 Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ............................................................................................................................1300 Failure code [DX20KY] Hot Short of Clutch Control Solenoid ...............................................................................................................................1302 Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. .................................................................................................................................1304 Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ..................................................................................................................................1306 Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. .....................................................................................................................................1308 Failure code [DXH7KA] Disconnection of Reverse Solenoid ..................................................................................................................................1310 Failure code [DXH7KB] Ground Fault of Reverse Solenoid ...................................................................................................................................1312 Failure code [DXH7KY] Hot Short of Reverse Solenoid ......................................................................................................................................1314 Failure code [DXH8KA] Disconnection of Forward Solenoid ..................................................................................................................................1316 Failure code [DXH8KB] Ground Fault of Forward Solenoid ...................................................................................................................................1318 Failure code [DXH8KY] Hot Short of Forward Solenoid ......................................................................................................................................1320 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ............................................................................................................................1322 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) .............................................................................................................................1324 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ................................................................................................................................1326 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ............................................................................................................................1327 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) .............................................................................................................................1329 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ................................................................................................................................1331 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...............................................................................................................................1332 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal .............................................................................................................................1335 Failure code [J141N1] Steering Pump Over Run .............................................................................................................................................1337 Failure code [LA00L3] Failure of Fan Reverse .............................................................................................................................................1338 Failure code [M100N1] HST Pump Over Run ..................................................................................................................................................1339 Failure code [M400N1] HST Motor 1 Over Run ...............................................................................................................................................1340 Troubleshooting of electrical system (E-mode) ................................................................................................................................................1341 E-1 Engine does not start ................................................................................................................................................................1341 E-2 Manual preheating system does not work ...............................................................................................................................................1348 E-3 Automatic preheating system does not work ............................................................................................................................................1351 E-4 While preheating is working, preheating monitor does not light up ....................................................................................................................1353 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .........................................................................................................1355 E-6 LCD unit on machine monitor displays nothing .........................................................................................................................................1358 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ................................................................................................1360 E-8 LCD on machine monitor does not display properly .....................................................................................................................................1362 E-9 Meter unit display on machine monitor is abnormal ....................................................................................................................................1364 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ....................................................................................................................1367 E-11 Caution LED on machine monitor is abnormal ..........................................................................................................................................1370 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ............................................................................................1372 E-13 Two switches operation of switch panel on machine monitor does not function .........................................................................................................1374 E-14 Switch panel buzzer of machine monitor is abnormal ..................................................................................................................................1377 E-15 Rearview monitor does not light up or backlight flickers ............................................................................................................................1379 E-16 Rearview monitor images are not displayed clearly ...................................................................................................................................1382 E-17 Rearview monitor brightness cannot be adjusted ......................................................................................................................................1385 E-18 Night lighting lamp of rearview monitor is abnormal .................................................................................................................................1388 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ................................................................................................1390 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ..................................................................................1391 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light .......................................................................................1395 E-22 The HST oil filter clogging caution lamp does not light up ..........................................................................................................................1397 E-23 Radiator coolant level caution lamp does not light ..................................................................................................................................1399 E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light .......................................................................1401 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 ....1402 E-26 Fuel level gauge does not indicate correct level ....................................................................................................................................1404 E-27 Seat belt caution lamp indication is abnormal .......................................................................................................................................1406 E-28 Horn does not sound .................................................................................................................................................................1407 E-29 Horn does not stop sounding .........................................................................................................................................................1410 E-30 Alarm buzzer does not sound .........................................................................................................................................................1412 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding .........................................................................................................1414 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 ................1415 E-33 Setting does not change while operating traction control switch .....................................................................................................................1417 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 .......................................................1419 E-35 Remote positioner does not work or cannot be released ...............................................................................................................................1422 E-36 Bucket positioner does not work or cannot be released ...............................................................................................................................1424 E-37 Direction selector (FNR) switch mode is not selected or not released ................................................................................................................1427 E-38 PZ auto tilt-in does not work .......................................................................................................................................................1429 E-39 Tracktion level does not display MAX when max traction switch is turned ON ..........................................................................................................1432 E-40 ECSS function cannot be selected or cannot be released ..............................................................................................................................1434 E-41 None of headlamp, clearance lamp, and tail lamp lights ..............................................................................................................................1436 E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out ..........................................................................................................1438 E-43 Both High and Low beams of headlamp do not light up or go out .......................................................................................................................1442 E-44 Low beam of headlamp does not light up or go out ....................................................................................................................................1446 E-45 High beam of headlamp does not light up or go out ...................................................................................................................................1448 E-46 Front working lamp does not light up or go out ......................................................................................................................................1450 E-47 Rear working lamp does not light up or go out .......................................................................................................................................1454 E-48 All of turn signal lamps and hazard lamps do not flash or go out ....................................................................................................................1458 E-49 Turn signal lamps do not flash or go out ............................................................................................................................................1461 E-50 Hazard lamp does not flash or go out ................................................................................................................................................1464 E-51 Brake lamp does not light or stays lighted ..........................................................................................................................................1467 E-52 Backup lamp does not light up or does not go out ....................................................................................................................................1470 E-53 Backup buzzer does not sound or continues to sound ..................................................................................................................................1473 E-54 Front wiper does not operate ........................................................................................................................................................1475 E-55 Rear wiper does not operate .........................................................................................................................................................1478 E-56 Window washer does not operate ......................................................................................................................................................1480 E-57 KOMTRAX system does not operate normally ............................................................................................................................................1483 Troubleshooting of hydraulic and mechanical system (H-mode) ..................................................................................................................................1485 Information described in troubleshooting table (H-mode) ..................................................................................................................................1485 System chart of hydraulic and mechanical systems .........................................................................................................................................1486 Failure mode and cause table .............................................................................................................................................................1488 H-1 Machine does not travel forward or backward ..........................................................................................................................................1495 H-2 Machine does not travel forward (Machine travels backward normally) ..................................................................................................................1498 H-3 Machine does not travel backward (Machine travels forward normally) ..................................................................................................................1499 H-4 Machine does not travel forward or backward fast .....................................................................................................................................1500 H-5 Machine does not travel forward fast (Machine travel backward fast) ..................................................................................................................1504 H-6 Machine does not travel backward fast (Machine travel forward fast) ..................................................................................................................1505 H-7 Machine lacks power neither when traveling forward nor backward ......................................................................................................................1506 H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ....................................................................................1509 H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ...................................................................................1510 H-10 Engine stalls during travel or engine speed drops significantly .....................................................................................................................1511 H-11 Steering wheel is too heavy to turn .................................................................................................................................................1512 H-12 Steering wheel is heavy to turn .....................................................................................................................................................1514 H-13 Machine sways or large shocks are made while machine turns ..........................................................................................................................1515 H-14 Machine unintentionally turns when machine travels ..................................................................................................................................1516 H-15 Wheel brakes do not work or are weak ................................................................................................................................................1517 H-16 Wheel brakes are not released or drag ...............................................................................................................................................1518 H-17 Parking brake does not work or it is weak ...........................................................................................................................................1519 H-18 Parking brake is not released or drags. .............................................................................................................................................1520 H-19 Boom does not rise ..................................................................................................................................................................1521 H-20 Boom moves slow or boom lacks lifting force .........................................................................................................................................1523 H-21 Rising boom slows down at certain height ............................................................................................................................................1525 H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground). .....................................................................................................1526 H-23 Hydraulic drift of boom is large ....................................................................................................................................................1527 H-24 Boom moves up and down during operation .............................................................................................................................................1528 H-25 Bucket does not tilt back ...........................................................................................................................................................1529 H-26 Bucket moves slow or lacks tilt-back force ..........................................................................................................................................1531 H-27 Bucket decelerates during tilt-back operation .......................................................................................................................................1533 H-28 Bucket cylinder does not hold bucket on ground ......................................................................................................................................1534 H-29 Hydraulic drift of bucket is large ..................................................................................................................................................1535 H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) .....................................................................................................1536 H-31 Boom and bucket control levers do not move smoothly and are heavy to move ...........................................................................................................1537 H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ..............................................................................................1538 H-33 Large shocks are made when work equipment starts to move and stops ..................................................................................................................1539 H-34 When certain work equipment is relieved hydraulically, other work equipment moves ...................................................................................................1540 H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ..............................................................................................................1541 H-36 Fan speed is abnormal (too high or low, or fan does not rotate) .....................................................................................................................1542 H-37 Unusual noise is heard from around fan ..............................................................................................................................................1544 Troubleshooting of engine (S-mode) ...........................................................................................................................................................1545 Information described in troubleshooting table (S mode) ..................................................................................................................................1545 S-1 Engine does not crank when starting switch is turned to START position ...............................................................................................................1546 S-2 Engine cranks but no exhaust smoke comes out .........................................................................................................................................1547 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .......................................................................................1548 S-4 Engine startability is poor ..........................................................................................................................................................1549 S-5 Engine does not pick up smoothly .....................................................................................................................................................1551 S-6 Engine stops during operation ........................................................................................................................................................1553 S-7 Engine runs rough or is unstable .....................................................................................................................................................1555 S-8 Engine lacks power ...................................................................................................................................................................1556 S-9 KDPF gets clogged in a short time ....................................................................................................................................................1558 S-10 Engine oil consumption is excessive .................................................................................................................................................1560 S-11 Engine oil becomes contaminated early ...............................................................................................................................................1561 S-12 Fuel consumption is excessive .......................................................................................................................................................1562 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....................................................................................................................1563 S-14 Oil pressure drops ..................................................................................................................................................................1564 S-15 Fuel mixes into engine oil ..........................................................................................................................................................1565 S-16 Water mixes into engine oil (milky) .................................................................................................................................................1566 S-17 Coolant temperature rises too high (overheating) ....................................................................................................................................1567 S-18 Unusual noise is heard ..............................................................................................................................................................1568 S-19 Vibration is excessive ..............................................................................................................................................................1569 S-20 Air cannot be bled from fuel circuit ................................................................................................................................................1571 S-21 Active regeneration is executed frequently ..........................................................................................................................................1572 S-22 Active regeneration takes time ......................................................................................................................................................1573 S-23 White smoke is exhausted during active regeneration .................................................................................................................................1574 50 Disassembly and assembly ......................................................................................................................................................................1575 Table of contents ............................................................................................................................................................................1576 Related information on disassembly and assembly ..............................................................................................................................................1578 How to read this manual ..................................................................................................................................................................1578 Coating materials list ...................................................................................................................................................................1580 Special tools list .......................................................................................................................................................................1584 Sketches of special tools ................................................................................................................................................................1591 Engine and cooling system ....................................................................................................................................................................1607 Removal and installation of supply pump assembly .........................................................................................................................................1607 Removal and installation of injector assembly ............................................................................................................................................1611 Removal and installation of cylinder head assembly .......................................................................................................................................1620 Removal and installation of engine hood assembly .........................................................................................................................................1627 Removal and installation of grille assembly ..............................................................................................................................................1630 Removal and installation of radiator core assembly .......................................................................................................................................1632 Removal and installation of aftercooler ..................................................................................................................................................1635 Removal and installation of hydraulic oil cooler .........................................................................................................................................1637 Removal and installation of engine assembly ..............................................................................................................................................1638 Removal and installation of engine front oil seal ........................................................................................................................................1644 Removal and installation of engine rear oil seal .........................................................................................................................................1647 Removal and installation of cooling fan and fan motor assembly ...........................................................................................................................1650 Removal and installation of KDPF assembly ................................................................................................................................................1652 Disassembly and assembly of KDPF assembly ................................................................................................................................................1656 Removal and installation of KCCV assembly ................................................................................................................................................1665 Removal and installation of air cleaner assembly .........................................................................................................................................1666 Removal and installation of KVGT assembly ................................................................................................................................................1668 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ...............................................................................................................1672 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ..............................................................................................................1674 Removal and installation of alternator belt ..............................................................................................................................................1677 Removal and installation of fuel tank assembly ...........................................................................................................................................1679 Power train ..................................................................................................................................................................................1682 Removal and installation of transfer assembly ............................................................................................................................................1682 Disassembly and assembly of transfer assembly ............................................................................................................................................1687 Disassembly and assembly of parking brake assembly .......................................................................................................................................1719 Disassembly and assembly of differential assembly ........................................................................................................................................1727 Removal and installation of front axle assembly ..........................................................................................................................................1751 Removal and installation of rear axle assembly ...........................................................................................................................................1753 Disassembly and assembly of axle housing assembly ........................................................................................................................................1756 Undercarriage and frame ......................................................................................................................................................................1765 Removal and installation of center hinge pin .............................................................................................................................................1765 Removal and installation of counterweight assembly .......................................................................................................................................1774 Hydraulic system .............................................................................................................................................................................1776 Removal and installation of hydraulic tank assembly ......................................................................................................................................1776 Removal and installation of control valve assembly .......................................................................................................................................1779 Disassembly and assembly of control valve assembly .......................................................................................................................................1783 Removal and installation of hydraulic pump assembly ......................................................................................................................................1786 Removal and installation of HST motor1 assembly ..........................................................................................................................................1790 Removal and installation of HST motor2 assembly ..........................................................................................................................................1792 Disassembly and assembly of hydraulic cylinder assembly ..................................................................................................................................1794 Work equipment ...............................................................................................................................................................................1801 Removal and installation of work equipment assembly ......................................................................................................................................1801 Cab and its attachments ......................................................................................................................................................................1807 Removal and installation of operator's cab and floor frame assembly ......................................................................................................................1807 Removal and installation of operator's cab glass (adhered glass) .........................................................................................................................1812 Removal and installation of operator's seat assembly .....................................................................................................................................1820 Removal and installation of seat belt ....................................................................................................................................................1822 Electrical system ............................................................................................................................................................................1823 Removal and installation of machine monitor assembly .....................................................................................................................................1823 Removal and installation of engine controller assembly ...................................................................................................................................1825 Removal and installation of HST controller assembly ......................................................................................................................................1827 Removal and installation of air conditioner controller assembly ..........................................................................................................................1829 Removal and installation of monitor controller assembly ..................................................................................................................................1830 Removal and installation of mass air flow and temperature sensor .........................................................................................................................1832 Removal and installation of KOMTRAX terminal assembly ....................................................................................................................................1833 Air conditioner unit .........................................................................................................................................................................1834 Removal and installation of air conditioner compressor ...................................................................................................................................1834 Removal and installation of air conditioner condenser ....................................................................................................................................1836 Removal and installation of air conditioner unit assembly ................................................................................................................................1838 60 Maintenance standard ..........................................................................................................................................................................1843 Table of contents ............................................................................................................................................................................1844 Engine and cooling system ....................................................................................................................................................................1845 Engine related parts .....................................................................................................................................................................1845 Cooling fan motor ........................................................................................................................................................................1846 Power train ..................................................................................................................................................................................1848 Damper ...................................................................................................................................................................................1848 Transfer .................................................................................................................................................................................1849 Drive shaft ..............................................................................................................................................................................1856 Axle .....................................................................................................................................................................................1857 Differential .............................................................................................................................................................................1859 Limited slip differential ................................................................................................................................................................1863 Final drive ..............................................................................................................................................................................1865 Steering system ..............................................................................................................................................................................1869 Steering column ..........................................................................................................................................................................1869 Priority valve ...........................................................................................................................................................................1870 Emergency steering valve .................................................................................................................................................................1871 Steering cylinder ........................................................................................................................................................................1872 Brake system .................................................................................................................................................................................1874 Brake accumulator charge valve ...........................................................................................................................................................1874 Slack adjuster ...........................................................................................................................................................................1875 Brake ....................................................................................................................................................................................1876 Parking brake ............................................................................................................................................................................1878 Parking brake solenoid valve .............................................................................................................................................................1879 Undercarriage and frame ......................................................................................................................................................................1880 Axle mount ...............................................................................................................................................................................1880 Center hinge pin .........................................................................................................................................................................1882 Hydraulic system .............................................................................................................................................................................1886 Hydraulic tank ...........................................................................................................................................................................1886 Double type gear pump ....................................................................................................................................................................1887 Steering and work equipment pump .........................................................................................................................................................1888 Control valve ............................................................................................................................................................................1892 Self-pressure reducing valve .............................................................................................................................................................1905 Work equipment PPC valve .................................................................................................................................................................1907 Work equipment lock solenoid valve .......................................................................................................................................................1909 Work equipment ...............................................................................................................................................................................1910 Work equipment linkage ...................................................................................................................................................................1910 Bucket ...................................................................................................................................................................................1914 Work equipment cylinder ..................................................................................................................................................................1916 Cab and its attachments ......................................................................................................................................................................1917 Cab mount ................................................................................................................................................................................1917 Electrical system ............................................................................................................................................................................1918 Bucket positioner ........................................................................................................................................................................1918 Fork positioner ..........................................................................................................................................................................1919 Remote boom positioner ...................................................................................................................................................................1920 80 Appendix ......................................................................................................................................................................................1921 Table of contents ............................................................................................................................................................................1922 Air conditioner components ...................................................................................................................................................................1923 Precautions for refrigerant ..............................................................................................................................................................1923 Air conditioner component ................................................................................................................................................................1924 Configuration and function of refrigeration cycle ........................................................................................................................................1926 Outline of refrigeration cycle ...........................................................................................................................................................1927 Air conditioner unit .....................................................................................................................................................................1929 Dual pressure switch .....................................................................................................................................................................1934 Air conditioner controller ...............................................................................................................................................................1935 Compressor ...............................................................................................................................................................................1936 Condenser ................................................................................................................................................................................1937 Receiver drier ...........................................................................................................................................................................1938 Sunlight sensor ..........................................................................................................................................................................1940 Outer temperature sensor (outside air temperature sensor) ................................................................................................................................1941 Procedure for testing and troubleshooting ................................................................................................................................................1942 Circuit diagram and arrangement of connector pins ........................................................................................................................................1944 System diagram ...........................................................................................................................................................................1947 Parts and connectors layout ..............................................................................................................................................................1950 Testing with self-diagnosis function .....................................................................................................................................................1955 How to open the electrical system abnormality record screen in service mode of the machine monitor .......................................................................................1956 Testing temperature control system .......................................................................................................................................................1958 Testing vent (mode) changeover ...........................................................................................................................................................1960 Testing FRESH/RECIRC air changeover ......................................................................................................................................................1962 Testing evaporator temperature sensor ....................................................................................................................................................1964 Testing relays ...........................................................................................................................................................................1966 Troubleshooting chart 1 ..................................................................................................................................................................1968 Troubleshooting chart 2 ..................................................................................................................................................................1969 Information in troubleshooting table .....................................................................................................................................................1971 Failure code list related to air conditioner .............................................................................................................................................1972 Failure code [879AKA] A/C Inner Sensor Open Circuit ......................................................................................................................................1973 Failure code [879AKB] A/C Inner Sensor Short Circuit .....................................................................................................................................1975 Failure code [879BKA] A/C Outer Sensor Open Circuit ......................................................................................................................................1977 Failure code [879BKB] A/C Outer Sensor Short Circuit .....................................................................................................................................1979 Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................................................................................................1981 Failure code [879CKB] Ventilating Sensor Short Circuit ...................................................................................................................................1983 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..............................................................................................................................1985 Failure code [879EMC] Ventilation Damper Abnormality .....................................................................................................................................1987 Failure code [879FMC] Air Mix Damper Abnormality .........................................................................................................................................1990 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) .....................................................................................1993 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................................................................................................1996 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...................................................................................................1999 A-4 Troubleshooting for FRESH/RECIRC air changeover ......................................................................................................................................2002 Troubleshooting with gauge pressure ......................................................................................................................................................2004 Connection of service tool ...............................................................................................................................................................2007 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ..................................................................................................2009 Handling of compressor oil ...............................................................................................................................................................2011 90 Diagrams and drawings .........................................................................................................................................................................2013 Table of contents ............................................................................................................................................................................2014 Hydraulic circuit diagram ....................................................................................................................................................................2015 Symbols in hydraulic circuit diagram .....................................................................................................................................................2015 Hydraulic circuit diagram ................................................................................................................................................................2019 Electric circuit diagram .....................................................................................................................................................................2020 Symbols in electric circuit diagram ......................................................................................................................................................2020 Electrical circuit diagram of machine body ...............................................................................................................................................2024 Electrical circuit diagram of floor ......................................................................................................................................................2028 INDEX.............................................................................................................................................................................................2036
KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL SEN06255-01 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
