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KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL VENBM28500 – PDF DOWNLOAD
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KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL VENBM28500 – PDF DOWNLOAD
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KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL VENBM28500 – PDF DOWNLOAD
Language : English
Pages : 2055
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL VENBM28500 – PDF DOWNLOAD
VENBM28500 WA270-7................................................................................................................................................................................ 1 00 Index and foreword ............................................................................................................................................................................ 3 Index ........................................................................................................................................................................................ 4 Foreword, safety and general information ..................................................................................................................................................... 19 Important safety notice .................................................................................................................................................................. 19 How to read the shop manual .............................................................................................................................................................. 26 Explanation of terms for maintenance standard ............................................................................................................................................ 28 Handling equipment of fuel system devices ................................................................................................................................................ 30 Handling of intake system parts .......................................................................................................................................................... 31 Handling of hydraulic equipment .......................................................................................................................................................... 32 Method of disconnecting and connecting of push-pull type coupler ......................................................................................................................... 34 Handling of electrical equipment ......................................................................................................................................................... 37 How to read electric wire code ........................................................................................................................................................... 45 Precautions when performing operation .................................................................................................................................................... 48 Practical use of KOMTRAX ................................................................................................................................................................. 53 Standard tightening torque table ......................................................................................................................................................... 54 List of abbreviation ..................................................................................................................................................................... 60 Conversion table ......................................................................................................................................................................... 65 01 Specification ................................................................................................................................................................................. 71 Table of contents ............................................................................................................................................................................ 72 Specifications ............................................................................................................................................................................... 73 Specification drawing .................................................................................................................................................................... 73 Specifications ........................................................................................................................................................................... 77 Weight table ............................................................................................................................................................................. 87 Table of fuel, coolant, and lubricants ................................................................................................................................................... 91 10 Structure and function ........................................................................................................................................................................ 93 Table of contents ............................................................................................................................................................................ 94 Engine and cooling system .................................................................................................................................................................... 96 Engine related parts ..................................................................................................................................................................... 96 KVGT ..................................................................................................................................................................................... 98 EGR system piping drawing ................................................................................................................................................................ 105 EGR system circuit diagram ............................................................................................................................................................... 107 EGR valve ................................................................................................................................................................................ 109 EGR cooler ............................................................................................................................................................................... 111 KCCV layout drawing ...................................................................................................................................................................... 112 KCCV ventilator .......................................................................................................................................................................... 114 KDPF ..................................................................................................................................................................................... 116 Cooling system ........................................................................................................................................................................... 120 Cooling fan motor ........................................................................................................................................................................ 122 Power train .................................................................................................................................................................................. 132 Power train system ....................................................................................................................................................................... 132 Layout of power train parts .............................................................................................................................................................. 134 Damper ................................................................................................................................................................................... 135 HST pump ................................................................................................................................................................................. 136 HST motor1 ............................................................................................................................................................................... 149 HST motor2 ............................................................................................................................................................................... 151 Transfer ................................................................................................................................................................................. 156 Clutch solenoid valve .................................................................................................................................................................... 163 Drive shaft .............................................................................................................................................................................. 165 Axle ..................................................................................................................................................................................... 166 Differential ............................................................................................................................................................................. 168 Torque proportional differential ......................................................................................................................................................... 172 Limited slip differential ................................................................................................................................................................ 174 Final drive .............................................................................................................................................................................. 179 Steering system .............................................................................................................................................................................. 182 Layout of steering devices ............................................................................................................................................................... 182 Steering column .......................................................................................................................................................................... 183 Priority valve ........................................................................................................................................................................... 184 Cushion valve ............................................................................................................................................................................ 188 Emergency steering valve ................................................................................................................................................................. 189 Orbitrol valve ........................................................................................................................................................................... 192 2way restrictor valve .................................................................................................................................................................... 198 Brake system ................................................................................................................................................................................. 199 Layout of brake parts .................................................................................................................................................................... 199 Brake accumulator charge valve ........................................................................................................................................................... 201 Brake valve .............................................................................................................................................................................. 206 Brake accumulator ........................................................................................................................................................................ 210 Slack adjuster ........................................................................................................................................................................... 211 Brake .................................................................................................................................................................................... 213 Parking brake control .................................................................................................................................................................... 216 Parking brake ............................................................................................................................................................................ 217 Parking brake solenoid valve ............................................................................................................................................................. 218 Undercarriage and frame ...................................................................................................................................................................... 220 Axle mount ............................................................................................................................................................................... 220 Center hinge pin ......................................................................................................................................................................... 222 Tire ..................................................................................................................................................................................... 223 Hydraulic system ............................................................................................................................................................................. 225 Hydraulic component layout ............................................................................................................................................................... 225 Work equipment control ................................................................................................................................................................... 227 Hydraulic tank ........................................................................................................................................................................... 228 Double type gear pump .................................................................................................................................................................... 231 Steering and work equipment pump ......................................................................................................................................................... 232 Control valve ............................................................................................................................................................................ 244 CLSS ..................................................................................................................................................................................... 254 Hydraulic circuit diagram and names of valves ............................................................................................................................................ 258 Self-pressure reducing valve ............................................................................................................................................................. 271 Work equipment PPC valve ................................................................................................................................................................. 276 Work equipment lock solenoid valve ....................................................................................................................................................... 284 PPC circuit accumulator .................................................................................................................................................................. 285 ECSS accumulator ......................................................................................................................................................................... 286 Work equipment ............................................................................................................................................................................... 287 Work equipment linkage ................................................................................................................................................................... 287 Bucket ................................................................................................................................................................................... 288 Cab and its attachments ...................................................................................................................................................................... 289 ROPS cab ................................................................................................................................................................................. 289 Cab mount ................................................................................................................................................................................ 291 Electrical system ............................................................................................................................................................................ 292 Engine control system .................................................................................................................................................................... 292 Preheating system ........................................................................................................................................................................ 295 Engine output limit function ............................................................................................................................................................. 297 Automatic warm-up function ............................................................................................................................................................... 298 Parking brake control system ............................................................................................................................................................. 299 System operating lamp function ........................................................................................................................................................... 303 Battery disconnect switch function ....................................................................................................................................................... 304 HST controller system .................................................................................................................................................................... 306 Machine monitor system ................................................................................................................................................................... 346 Rearview monitor system .................................................................................................................................................................. 367 KOMTRAX system ........................................................................................................................................................................... 370 System component parts ................................................................................................................................................................... 373 Sensor ................................................................................................................................................................................... 396 20 Standard value tables ......................................................................................................................................................................... 417 Table of contents ............................................................................................................................................................................ 418 Standard service value table ................................................................................................................................................................. 419 Standard value table for engine .......................................................................................................................................................... 419 Standard value table for machine ......................................................................................................................................................... 421 Standard value table for electrical system ............................................................................................................................................... 433 30 Testing and adjusting ......................................................................................................................................................................... 443 Table of contents ............................................................................................................................................................................ 444 Related information on testing and adjusting ................................................................................................................................................. 446 Tools for testing and adjusting .......................................................................................................................................................... 446 Sketch of tools for testing and adjusting ................................................................................................................................................ 452 Engine and cooling system .................................................................................................................................................................... 453 Testing engine speed ..................................................................................................................................................................... 453 Testing boost pressure ................................................................................................................................................................... 454 Testing exhaust gas temperature .......................................................................................................................................................... 456 Testing exhaust gas color ................................................................................................................................................................ 457 Testing and adjusting valve clearance .................................................................................................................................................... 459 Testing compression pressure ............................................................................................................................................................. 461 Testing blowby pressure .................................................................................................................................................................. 465 Testing engine oil pressure .............................................................................................................................................................. 466 Testing EGR valve and KVGT driving oil pressure .......................................................................................................................................... 467 Testing fuel pressure .................................................................................................................................................................... 468 Testing fuel discharge, return and leakage ............................................................................................................................................... 472 Bleeding air from fuel system ............................................................................................................................................................ 477 Testing fuel circuit for leakage ......................................................................................................................................................... 479 Handling cylinder cutout mode operation .................................................................................................................................................. 480 Handling no-injection cranking operation ................................................................................................................................................. 481 Testing of KDPF and muffler stack for looseness and damage ............................................................................................................................... 482 Testing of installed condition of cylinder heads and manifolds ........................................................................................................................... 483 Testing engine piping for damage and looseness ........................................................................................................................................... 484 Testing and adjusting air conditioner compressor belt tension ............................................................................................................................ 485 Replacing alternator belt ................................................................................................................................................................ 486 Power train .................................................................................................................................................................................. 487 Testing oil leakage from axle final drive ................................................................................................................................................ 487 Testing drive shaft for looseness, backlash, and damage .................................................................................................................................. 488 Testing accelerator pedal ................................................................................................................................................................ 489 Testing and adjusting HST oil pressure ................................................................................................................................................... 490 Testing transfer clutch control pressure ................................................................................................................................................. 493 Steering system .............................................................................................................................................................................. 494 Testing directional lever ................................................................................................................................................................ 494 Testing steering wheel ................................................................................................................................................................... 495 Testing work equipment control lever ..................................................................................................................................................... 497 Testing and adjusting steering circuit oil pressure ...................................................................................................................................... 499 Bleeding air from steering cylinder circuit .............................................................................................................................................. 501 Brake system ................................................................................................................................................................................. 502 Testing brake pedal ...................................................................................................................................................................... 502 Testing braking performance .............................................................................................................................................................. 503 Testing and adjusting of accumulator charge pressure ..................................................................................................................................... 504 Testing wheel brake oil pressure ......................................................................................................................................................... 506 Testing lowering of wheel brake pressure ................................................................................................................................................. 507 Testing wear of wheel brake disc ......................................................................................................................................................... 509 Bleeding air from wheel brake circuit .................................................................................................................................................... 510 Releasing remaining pressure in brake accumulator circuit ................................................................................................................................ 511 Testing parking brake performance ........................................................................................................................................................ 512 Testing wear of parking brake disc ....................................................................................................................................................... 513 Testing parking brake release pressure ................................................................................................................................................... 514 Method of releasing parking brake manually ............................................................................................................................................... 515 Hydraulic system ............................................................................................................................................................................. 516 Testing cooling fan speed ................................................................................................................................................................ 516 Testing cooling fan pump circuit oil pressure ............................................................................................................................................ 517 Bleeding air from hydraulic fan circuit .................................................................................................................................................. 519 Testing and adjusting work equipment PPC oil pressure .................................................................................................................................... 520 Testing and adjusting work equipment oil pressure ........................................................................................................................................ 522 Bleeding air from work equipment circuit ................................................................................................................................................. 526 Releasing remaining pressure from work equipment circuit ................................................................................................................................. 527 Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas .................................................................................. 529 Work equipment ............................................................................................................................................................................... 533 Testing and adjusting bucket positioner and bucket proximity switch ...................................................................................................................... 533 Testing and adjusting boom position detection lever ...................................................................................................................................... 535 Electrical system ............................................................................................................................................................................ 536 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ................................................................................................... 536 Special functions of machine monitor ..................................................................................................................................................... 537 Adjusting rearview camera angle .......................................................................................................................................................... 615 Handling voltage circuit of engine controller ............................................................................................................................................ 616 Handling battery disconnect switch ....................................................................................................................................................... 617 Testing diodes ........................................................................................................................................................................... 618 Pm clinic .................................................................................................................................................................................... 619 Pm Clinic service ........................................................................................................................................................................ 619 Check sheet .............................................................................................................................................................................. 620 40 Troubleshooting ............................................................................................................................................................................... 625 Table of contents ............................................................................................................................................................................ 626 Related information on troubleshooting ....................................................................................................................................................... 635 Troubleshooting points ................................................................................................................................................................... 635 Sequence of events in troubleshooting .................................................................................................................................................... 637 Checks before troubleshooting ............................................................................................................................................................ 639 Inspection procedure before troubleshooting .............................................................................................................................................. 641 Preparation for troubleshooting of electrical system ..................................................................................................................................... 658 Classification and procedures for troubleshooting ........................................................................................................................................ 664 Symptom and troubleshooting numbers ...................................................................................................................................................... 667 Information described in troubleshooting table ........................................................................................................................................... 670 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit .................................................................................................. 672 Connector list and layout ................................................................................................................................................................ 675 Connector contact identification ......................................................................................................................................................... 689 T-branch box and T-branch adapter table .................................................................................................................................................. 727 Fuse location table ...................................................................................................................................................................... 732 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ............................................................................................................................ 735 Precautions when performing troubleshooting of machine monitor ........................................................................................................................... 738 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit .................................................................................................. 740 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .......................................................................................................... 745 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) .............................................................................................. 746 Failure codes table ...................................................................................................................................................................... 747 Troubleshooting by failure code (Display of code) ............................................................................................................................................ 759 Failure code [2F00MA] Failure of Parking Brake Circuit ................................................................................................................................... 759 Failure code [2F00MB] Malfunction of Parking Brake ....................................................................................................................................... 762 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................................................................................................... 764 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ................................................................................................................................ 766 Failure code [6091NX] HST Oil Filter Clogging ............................................................................................................................................ 768 Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ......................................................................................................................... 770 Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. .......................................................................................................................... 772 Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ............................................................................................................................. 774 Failure code [879AKA] A/C Inner Sensor Open Circuit ...................................................................................................................................... 776 Failure code [879AKB] A/C Inner Sensor Short Circuit ..................................................................................................................................... 777 Failure code [879BKA] A/C Outer Sensor Open Circuit ...................................................................................................................................... 778 Failure code [879BKB] A/C Outer Sensor Short Circuit ..................................................................................................................................... 779 Failure code [879CKA] Ventilating Sensor Open Circuit .................................................................................................................................... 780 Failure code [879CKB] Ventilating Sensor Short Circuit ................................................................................................................................... 781 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................................................................................................. 782 Failure code [879EMC] Ventilation Damper Abnormality ..................................................................................................................................... 783 Failure code [879FMC] Air Mix Damper Abnormality ......................................................................................................................................... 784 Failure code [989L00] Engine Controller Lock Caution 1 ................................................................................................................................... 785 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................................................................................... 786 Failure code [989N00] Engine Controller Lock Caution 3 ................................................................................................................................... 787 Failure code [A1U0N3] HC Desorb Request 1 ................................................................................................................................................ 788 Failure code [A1U0N4] HC Desorb Request 2 ................................................................................................................................................ 790 Failure code [B@BAZG] Eng Oil Press Low .................................................................................................................................................. 792 Failure code [B@BCNS] Eng Water Overheat ................................................................................................................................................. 793 Failure code [B@BCZK] Eng Water Level Low ................................................................................................................................................ 794 Failure code [B@CRNS] HST Oil Temp. Overheat ............................................................................................................................................. 796 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................................................................................................... 797 Failure code [CA122] Chg Air Press Sensor High Error ..................................................................................................................................... 798 Failure code [CA123] Chg Air Press Sensor Low Error ...................................................................................................................................... 800 Failure code [CA131] Throttle Sensor High Error .......................................................................................................................................... 802 Failure code [CA132] Throttle Sensor Low Error ........................................................................................................................................... 804 Failure code [CA144] Coolant Temp Sens High Error ........................................................................................................................................ 806 Failure code [CA145] Coolant Temp Sens Low Error ......................................................................................................................................... 808 Failure code [CA153] Chg Air Temp Sensor High Error ...................................................................................................................................... 810 Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................................................................................................... 812 Failure code [CA187] Sensor 2 Supply Volt Low Error ...................................................................................................................................... 814 Failure code [CA221] Ambient Press Sensor High Error ..................................................................................................................................... 816 Failure code [CA222] Ambient Press Sensor Low Error ...................................................................................................................................... 818 Failure code [CA227] Sensor 2 Supply Volt High Error ..................................................................................................................................... 820 Failure code [CA234] Eng Overspeed ....................................................................................................................................................... 821 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................................................................................................... 822 Failure code [CA239] Ne Speed Sens Supply Volt High Error ................................................................................................................................ 823 Failure code [CA271] IMV/PCV1 Short Error ................................................................................................................................................ 824 Failure code [CA272] IMV/PCV1 Open Error ................................................................................................................................................. 826 Failure code [CA295] Ambient Press Sens In Range Error ................................................................................................................................... 828 Failure code [CA322] Inj #1(L#1) Open/Short Error ........................................................................................................................................ 829 Failure code [CA323] Inj #5(L#5) Open/Short Error ........................................................................................................................................ 831 Failure code [CA324] Inj #3(L#3) Open/Short Error ........................................................................................................................................ 833 Failure code [CA325] Inj #6(L#6) Open/Short Error ........................................................................................................................................ 835 Failure code [CA331] Inj #2(L#2) Open/Short Error ........................................................................................................................................ 837 Failure code [CA332] Inj #4(L#4) Open/Short Error ........................................................................................................................................ 839 Failure code [CA343] ECM Critical Internal Failure ....................................................................................................................................... 841 Failure code [CA351] Injectors Drive Circuit Error ....................................................................................................................................... 842 Failure code [CA352] Sensor 1 Supply Volt Low Error ...................................................................................................................................... 843 Failure code [CA356] Mass Air Flow Sensor High Error ..................................................................................................................................... 845 Failure code [CA357] Mass Air Flow Sensor Low Error ...................................................................................................................................... 847 Failure code [CA386] Sensor 1 Supply Volt High Error ..................................................................................................................................... 849 Failure code [CA428] Water in Fuel Sensor High Error ..................................................................................................................................... 850 Failure code [CA429] Water in Fuel Sensor Low Error ...................................................................................................................................... 852 Failure code [CA431] Idle Validation Sw Error ............................................................................................................................................ 854 Failure code [CA432] Idle Validation Process Error ....................................................................................................................................... 857 Failure code [CA435] Eng Oil Press Sw Error .............................................................................................................................................. 860 Failure code [CA441] Battery Voltage Low Error ........................................................................................................................................... 861 Failure code [CA442] Battery Voltage High Error .......................................................................................................................................... 863 Failure code [CA449] Rail Press Very High Error .......................................................................................................................................... 864 Failure code [CA451] Rail Press Sensor High Error ........................................................................................................................................ 865 Failure code [CA452] Rail Press Sensor Low Error ......................................................................................................................................... 867 Failure code [CA488] Chg Air Temp High Torque Derate ..................................................................................................................................... 869 Failure code [CA515] Rail Press Sens Sup Volt High Error ................................................................................................................................. 870 Failure code [CA516] Rail Press Sens Sup Volt Low Error .................................................................................................................................. 872 Failure code [CA553] Rail Press High Error ............................................................................................................................................... 874 Failure code [CA555] Crankcase Press High Error 1 ........................................................................................................................................ 875 Failure code [CA556] Crankcase Press High Error 2 ........................................................................................................................................ 876 Failure code [CA559] Rail Press Low Error ................................................................................................................................................ 877 Failure code [CA595] Turbo Speed High Error 2 ............................................................................................................................................ 879 Failure code [CA687] Turbo Speed Low Error ............................................................................................................................................... 880 Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................................................................................... 882 Failure code [CA691] Intake Air Temp Sens High Error ..................................................................................................................................... 884 Failure code [CA692] Intake Air Temp Sens Low Error ...................................................................................................................................... 886 Failure code [CA697] ECM Internal Temp Sensor High Error ................................................................................................................................. 888 Failure code [CA698] ECM Int Temp Sensor Low Error ....................................................................................................................................... 889 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..................................................................................................................................... 890 Failure code [CA778] Eng Bkup Speed Sensor Error ......................................................................................................................................... 892 Failure code [CA1117] Persistent Data Lost Error ......................................................................................................................................... 897 Failure code [CA1664] KDOC Malfunction ................................................................................................................................................... 898 Failure code [CA1691] Regeneration Ineffective ........................................................................................................................................... 901 Failure code [CA1695] Sensor 5 Supply Volt High Error .................................................................................................................................... 904 Failure code [CA1696] Sensor 5 Supply Volt Low Error ..................................................................................................................................... 905 Failure code [CA1843] Crankcase Press Sens High Error .................................................................................................................................... 907 Failure code [CA1844] Crankcase Press Sens Low Error ..................................................................................................................................... 909 Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................................................................................................... 911 Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................................................................................................... 913 Failure code [CA1883] KDPF Delta P Sens In Range Error ................................................................................................................................... 915 Failure code [CA1921] KDPF Soot Load High Error 1 ........................................................................................................................................ 919 Failure code [CA1922] KDPF Soot Load High Error 2 ........................................................................................................................................ 922 Failure code [CA1942] Crankcase Press Sens In Range Error ................................................................................................................................ 927 Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................................................................................................... 928 Failure code [CA2185] Throt Sensor Sup Volt High Error ................................................................................................................................... 931 Failure code [CA2186] Throt Sensor Sup Volt Low Error .................................................................................................................................... 933 Failure code [CA2249] Rail Press Very Low Error .......................................................................................................................................... 935 Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................................................................................................... 936 Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................................................................................................... 938 Failure code [CA2288] Turbo Speed High Error 1 ........................................................................................................................................... 941 Failure code [CA2311] IMV Solenoid Error ................................................................................................................................................. 942 Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................................................................................................... 943 Failure code [CA2353] EGR Valve Solenoid Short Error ..................................................................................................................................... 945 Failure code [CA2357] EGR Valve Servo Error .............................................................................................................................................. 947 Failure code [CA2373] Exhaust Manifold Press Sens High error ............................................................................................................................. 948 Failure code [CA2374] Exhaust Manifold Press Sens Low error .............................................................................................................................. 950 Failure code [CA2375] EGR Orifice Temp Sens High Error ................................................................................................................................... 952 Failure code [CA2376] EGR Orifice Temp Sens Low Error .................................................................................................................................... 954 Failure code [CA2381] KVGT Pos Sens High Error ........................................................................................................................................... 956 Failure code [CA2382] KVGT Pos Sens Low Error ............................................................................................................................................ 958 Failure code [CA2383] KVGT Solenoid Open Error ........................................................................................................................................... 961 Failure code [CA2386] KVGT Solenoid Short Error .......................................................................................................................................... 963 Failure code [CA2387] KVGT Servo Error ................................................................................................................................................... 965 Failure code [CA2554] Exh Manifold Press Sens In Range Error ............................................................................................................................. 966 Failure code [CA2555] Grid Htr Relay Volt Low Error ...................................................................................................................................... 967 Failure code [CA2556] Grid Htr Relay Volt High Error ..................................................................................................................................... 969 Failure code [CA2637] KDOC Face Plugging ................................................................................................................................................. 971 Failure code [CA2639] Manual Stationary Regeneration Request ............................................................................................................................. 973 Failure code [CA2961] EGR Orifice Temp High Error 1 ...................................................................................................................................... 976 Failure code [CA2973] Chg Air Press Sensor In Range Error ................................................................................................................................ 977 Failure code [CA3133] KDPF Outlet Press Sens High Error .................................................................................................................................. 978 Failure code [CA3134] KDPF Outlet Press Sens Low Error ................................................................................................................................... 980 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .............................................................................................................................. 982 Failure code [CA3251] KDOC Inlet Temp High Error ......................................................................................................................................... 986 Failure code [CA3253] KDOC Temp Error - Non Regeneration ................................................................................................................................. 989 Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................................................................................................... 992 Failure code [CA3255] KDPF Temp Error - Non Regeneration ................................................................................................................................. 995 Failure code [CA3256] KDPF Outlet Temp High Error 1 ...................................................................................................................................... 998 Failure code [CA3311] KDOC Outlet Temp High Error 2 ......................................................................................................................................1001 Failure code [CA3312] KDPF Outlet Temp High Error 2 ......................................................................................................................................1004 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...................................................................................................................................1007 Failure code [CA3314] KDOC Inlet Temp Sens High Error ....................................................................................................................................1010 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ................................................................................................................................1013 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....................................................................................................................................1017 Failure code [CA3317] KDOC Outlet Temp Sens High Error ...................................................................................................................................1020 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...............................................................................................................................1023 Failure code [CA3319] KDPF Outlet Temp Sens High Error ...................................................................................................................................1027 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....................................................................................................................................1030 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...............................................................................................................................1033 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...........................................................................................................................1037 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ............................................................................................................................1039 Failure code [CA3741] Rail Press Valve Trip Error ........................................................................................................................................1041 Failure code [D110L4] Disconnection of Battery Relay Signal ..............................................................................................................................1042 Failure code [D160KA] Disconnection of Backup Lamp Relay Output ..........................................................................................................................1044 Failure code [D160KY] Hot Short of Backup Lamp Relay Output ..............................................................................................................................1046 Failure code [D191KA] Disconnection of Neutral Output Relay ..............................................................................................................................1048 Failure code [D191KB] Ground Fault of Neutral Output Relay ...............................................................................................................................1050 Failure code [D191KY] Hot Short of Neutral Output Relay ..................................................................................................................................1052 Failure code [D192KA] Disconnection of ECSS Solenoid .....................................................................................................................................1054 Failure code [D192KB] Ground Fault of ECSS Solenoid ......................................................................................................................................1056 Failure code [D192KY] Hot Short of ECSS Solenoid .........................................................................................................................................1057 Failure code [D19JKZ] Personal Code Relay Abnormality ....................................................................................................................................1058 Failure code [D1B0KA] Disconnection of HST Safety Relay ..................................................................................................................................1060 Failure code [D1B0KB] Ground Fault of HST Safety Relay ...................................................................................................................................1062 Failure code [D1B0KY] Hot Short of HST Safety Relay ......................................................................................................................................1064 Failure code [D1B0MC] Malfunction of HST Safety Relay ....................................................................................................................................1066 Failure code [D1E6KA] Disconnection of Parking Brake Relay ...............................................................................................................................1067 Failure code [D1E6KB] Ground Fault of Parking Brake Relay ................................................................................................................................1069 Failure code [D1E6KY] Hot Short of Parking Brake Relay ...................................................................................................................................1071 Failure code [D5ZHKA] Failure of Key SW C Signal .........................................................................................................................................1073 Failure code [D5ZHKB] Key SW C Signal Short Circuit ......................................................................................................................................1075 Failure code [D5ZHL6] Disconnection of Key SW C ..........................................................................................................................................1077 Failure code [D811MC] KOMTRAX Error ......................................................................................................................................................1078 Failure code [D862KA] GPS Antenna Open Circuit ...........................................................................................................................................1079 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ..............................................................................................................................1080 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .............................................................................................................................1082 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ............................................................................................................................................1084 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..............................................................................................................................................1085 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...........................................................................................................................1087 Failure code [DAF0MB] Monitor ROM Abnormality ............................................................................................................................................1088 Failure code [DAF0MC] Monitor Error ......................................................................................................................................................1089 Failure code [DAF3KK] Controller Power Source Low (MON) ..................................................................................................................................1090 Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................................................................................................1092 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .............................................................................................................................1093 Failure code [DAFGMC] GPS Module Error ...................................................................................................................................................1094 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ..................................................................................................................................1095 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) .................................................................................................................................1097 Failure code [DAFQKR] CAN2 Discon (Monitor) ..............................................................................................................................................1099 Failure code [DAJ0KK] Controller Power Source Low (HST) ..................................................................................................................................1100 Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ...........................................................................................................................1103 Failure code [DAJ0MC] HST Con Error ......................................................................................................................................................1104 Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ..................................................................................................................................1105 Failure code [DAJ2KK] Solenoid Power Source Low (HST) ....................................................................................................................................1107 Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ............................................................................................................................1110 Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay .................................................................................................................................1112 Failure code [DAJ5KX] Failure of 5V Power Source 0 .......................................................................................................................................1114 Failure code [DAJ6KX] Failure of 5V Power Source 1 .......................................................................................................................................1116 Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) .............................................................................................................................1118 Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ..................................................................................................................................1119 Failure code [DAJLKB] Operating Lamp Short Circuit (HST) .................................................................................................................................1121 Failure code [DAJQKR] CAN2 Discon ( HST Con) .............................................................................................................................................1123 Failure code [DAJRKR] CAN1 Discon ( HST Con) .............................................................................................................................................1124 Failure code [DAJRMA] Inconsistency of Option Selection (HST) ............................................................................................................................1125 Failure code [DAZ9KQ] A/C Model Selection Abnormality ....................................................................................................................................1126 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...........................................................................................................................................1127 Failure code [DB2QKR] CAN2 Discon (Engine Con) ...........................................................................................................................................1128 Failure code [DB2RKR] CAN1 Discon (Engine Con) ...........................................................................................................................................1133 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...........................................................................................................................1137 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch .........................................................................................................................1139 Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ................................................................................................................................1141 Failure code [DDB6L4] Parking Brake Signal Malfunction ...................................................................................................................................1143 Failure code [DDD7KA] Failure of Variable Speed Control ..................................................................................................................................1146 Failure code [DDD7KY] Hot Short of Variable Speed Control ................................................................................................................................1148 Failure code [DDK3KA] FNR SW Input Signal Disconnection ..................................................................................................................................1150 Failure code [DDK3KB] FNR SW Input Signal Short Circuit ..................................................................................................................................1152 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...............................................................................................................................1154 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...............................................................................................................................1157 Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ............................................................................................................................1159 Failure code [DF10KA] Disconnection of Speed Range Input .................................................................................................................................1161 Failure code [DF10KB] Ground Fault of Speed Range Input ..................................................................................................................................1164 Failure code [DGH1KX] Out of Range of HST Oil Temp. Sensor ...............................................................................................................................1167 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor .............................................................................................................................1169 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ..................................................................................................................................1171 Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ...........................................................................................................................1173 Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) .........................................................................................................................1175 Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ...........................................................................................................................1177 Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) .........................................................................................................................1179 Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) .............................................................................................................................1181 Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ...........................................................................................................................1183 Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ...........................................................................................................................1185 Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. .........................................................................................................................1187 Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ............................................................................................................................1189 Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ..........................................................................................................................1191 Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ............................................................................................................................1193 Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ..........................................................................................................................1195 Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ...........................................................................................................................1197 Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit .........................................................................................................................1199 Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ...........................................................................................................................1201 Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit .........................................................................................................................1203 Failure code [DHT8ZG] Steering Oil Pressure Low ..........................................................................................................................................1205 Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ...........................................................................................................................1206 Failure code [DJF1KA] Disconnection of Fuel Level Sensor .................................................................................................................................1208 Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................................................................................................1210 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ............................................................................................................................1213 Failure code [DK55L5] Failure of FNR Lever Potentio ......................................................................................................................................1215 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...............................................................................................................................1216 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) .............................................................................................................................1219 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...........................................................................................................................1222 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ................................................................................................................................1225 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ..............................................................................................................................1228 Failure code [DK70KA] Failure of inching sensor Circuit ..................................................................................................................................1231 Failure code [DK70KY] Hot Short of inching sensor Circuit ................................................................................................................................1234 Failure code [DKA0KA] Failure of Boom Angle Sensor .......................................................................................................................................1236 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .............................................................................................................................1238 Failure code [DKA0L0] Boom Angle Sensor Dislocation ......................................................................................................................................1240 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor .........................................................................................................................1242 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...............................................................................................................................1244 Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ...........................................................................................................................1246 Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ...........................................................................................................................1248 Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ...............................................................................................................................1250 Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ..............................................................................................................................1253 Failure code [DPQ1KR] LIN Discon (Switch Panel) ..........................................................................................................................................1255 Failure code [DPQ2KR] LIN Discon (LED Unit) ..............................................................................................................................................1258 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) .....................................................................................................................................1261 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...........................................................................................................................................1264 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ............................................................................................................................1266 Failure code [DV00KB] Ground Fault of Buzzer Output ......................................................................................................................................1268 Failure code [DW26KA] Disconnection of Motor 2 Solenoid ..................................................................................................................................1270 Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ...................................................................................................................................1272 Failure code [DW26KY] Hot Short of Motor 2 Solenoid ......................................................................................................................................1274 Failure code [DW4BKA] Disconnection of Parking Brake Valve ...............................................................................................................................1276 Failure code [DW4BKB] Ground Fault of Parking Brake Valve ................................................................................................................................1278 Failure code [DW4BKY] Hot Short of Parking Brake Valve ...................................................................................................................................1280 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ............................................................................................................................1281 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .........................................................................................................................1283 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ............................................................................................................................1285 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid .............................................................................................................................1286 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ..............................................................................................................................1288 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid .................................................................................................................................1290 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ............................................................................................................................1291 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) .............................................................................................................................1293 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ................................................................................................................................1295 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..........................................................................................................................1297 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...........................................................................................................................1299 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ..............................................................................................................................1301 Failure code [DX19KA] Disconnection of Motor 1 Solenoid ..................................................................................................................................1302 Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ...................................................................................................................................1304 Failure code [DX19KY] Hot Short of Motor 1 Solenoid ......................................................................................................................................1306 Failure code [DX20KA] Disconnection of Clutch Control Solenoid ...........................................................................................................................1308 Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ............................................................................................................................1310 Failure code [DX20KY] Hot Short of Clutch Control Solenoid ...............................................................................................................................1312 Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. .................................................................................................................................1314 Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ..................................................................................................................................1316 Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. .....................................................................................................................................1318 Failure code [DXH7KA] Disconnection of Reverse Solenoid ..................................................................................................................................1320 Failure code [DXH7KB] Ground Fault of Reverse Solenoid ...................................................................................................................................1322 Failure code [DXH7KY] Hot Short of Reverse Solenoid ......................................................................................................................................1324 Failure code [DXH8KA] Disconnection of Forward Solenoid ..................................................................................................................................1326 Failure code [DXH8KB] Ground Fault of Forward Solenoid ...................................................................................................................................1328 Failure code [DXH8KY] Hot Short of Forward Solenoid ......................................................................................................................................1330 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ............................................................................................................................1332 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) .............................................................................................................................1334 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ................................................................................................................................1336 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ............................................................................................................................1337 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) .............................................................................................................................1339 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ................................................................................................................................1341 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...............................................................................................................................1342 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal .............................................................................................................................1345 Failure code [J141N1] Steering Pump Over Run .............................................................................................................................................1347 Failure code [LA00L3] Failure of Fan Reverse .............................................................................................................................................1348 Failure code [M100N1] HST Pump Over Run ..................................................................................................................................................1349 Failure code [M400N1] HST Motor 1 Over Run ...............................................................................................................................................1350 Troubleshooting of electrical system (E-mode) ................................................................................................................................................1351 E-1 Engine does not start ................................................................................................................................................................1351 E-2 Manual preheating system does not work ...............................................................................................................................................1358 E-3 Automatic preheating system does not work ............................................................................................................................................1361 E-4 While preheating is working, preheating monitor does not light up ....................................................................................................................1363 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .........................................................................................................1365 E-6 LCD unit on machine monitor displays nothing .........................................................................................................................................1368 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ................................................................................................1370 E-8 LCD on machine monitor does not display properly .....................................................................................................................................1372 E-9 Meter unit display on machine monitor is abnormal ....................................................................................................................................1374 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ....................................................................................................................1377 E-11 Caution LED on machine monitor is abnormal ..........................................................................................................................................1380 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ............................................................................................1382 E-13 Two switches operation of switch panel on machine monitor does not function .........................................................................................................1384 E-14 Switch panel buzzer of machine monitor is abnormal ..................................................................................................................................1387 E-15 Rearview monitor does not light up or backlight flickers ............................................................................................................................1389 E-16 Rearview monitor images are not displayed clearly ...................................................................................................................................1392 E-17 Rearview monitor brightness cannot be adjusted ......................................................................................................................................1395 E-18 Night lighting lamp of rearview monitor is abnormal .................................................................................................................................1398 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ................................................................................................1400 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ..................................................................................1401 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light .......................................................................................1405 E-22 The HST oil filter clogging caution lamp does not light up ..........................................................................................................................1407 E-23 Radiator coolant level caution lamp does not light ..................................................................................................................................1409 E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light .......................................................................1411 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 ....1412 E-26 Fuel level gauge does not indicate correct level ....................................................................................................................................1414 E-27 Seat belt caution lamp indication is abnormal .......................................................................................................................................1416 E-28 Horn does not sound .................................................................................................................................................................1417 E-29 Horn does not stop sounding .........................................................................................................................................................1420 E-30 Alarm buzzer does not sound .........................................................................................................................................................1422 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding .........................................................................................................1424 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 ................1425 E-33 Setting does not change while operating traction control switch .....................................................................................................................1427 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 .......................................................1429 E-35 Remote positioner does not work or cannot be released ...............................................................................................................................1432 E-36 Bucket positioner does not work or cannot be released ...............................................................................................................................1434 E-37 Direction selector (FNR) switch mode is not selected or not released ................................................................................................................1437 E-38 PZ auto tilt-in does not work .......................................................................................................................................................1439 E-39 Tracktion level does not display MAX when max traction switch is turned ON ..........................................................................................................1442 E-40 ECSS function cannot be selected or cannot be released ..............................................................................................................................1444 E-41 None of headlamp, clearance lamp, and tail lamp lights ..............................................................................................................................1446 E-42 Clearance lamp, tail lamp and license-plate lamp do not light up or go out ..........................................................................................................1448 E-43 Both High and Low beams of headlamp do not light up or go out .......................................................................................................................1452 E-44 Low beam of headlamp does not light up or go out ....................................................................................................................................1456 E-45 High beam of headlamp does not light up or go out ...................................................................................................................................1458 E-46 Front working lamp does not light up or go out ......................................................................................................................................1460 E-47 Rear working lamp does not light up or go out .......................................................................................................................................1464 E-48 All of turn signal lamps and hazard lamps do not flash or go out ....................................................................................................................1468 E-49 Turn signal lamps do not flash or go out ............................................................................................................................................1471 E-50 Hazard lamp does not flash or go out ................................................................................................................................................1474 E-51 Brake lamp does not light or stays lighted ..........................................................................................................................................1477 E-52 Backup lamp does not light up or does not go out ....................................................................................................................................1480 E-53 Backup buzzer does not sound or continues to sound ..................................................................................................................................1483 E-54 Front wiper does not operate ........................................................................................................................................................1485 E-55 Rear wiper does not operate .........................................................................................................................................................1488 E-56 Window washer does not operate ......................................................................................................................................................1490 E-57 KOMTRAX system does not operate normally ............................................................................................................................................1493 Troubleshooting of hydraulic and mechanical system (H-mode) ..................................................................................................................................1495 Information described in troubleshooting table (H-mode) ..................................................................................................................................1495 System chart of hydraulic and mechanical systems .........................................................................................................................................1496 Failure mode and cause table .............................................................................................................................................................1498 H-1 Machine does not travel forward or backward ..........................................................................................................................................1505 H-2 Machine does not travel forward (Machine travels backward normally) ..................................................................................................................1508 H-3 Machine does not travel backward (Machine travels forward normally) ..................................................................................................................1509 H-4 Machine does not travel forward or backward fast .....................................................................................................................................1510 H-5 Machine does not travel forward fast (Machine travel backward fast) ..................................................................................................................1514 H-6 Machine does not travel backward fast (Machine travel forward fast) ..................................................................................................................1515 H-7 Machine lacks power neither when traveling forward nor backward ......................................................................................................................1516 H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ....................................................................................1519 H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ...................................................................................1520 H-10 Engine stalls during travel or engine speed drops significantly .....................................................................................................................1521 H-11 Steering wheel is too heavy to turn .................................................................................................................................................1522 H-12 Steering wheel is heavy to turn .....................................................................................................................................................1524 H-13 Machine sways or large shocks are made while machine turns ..........................................................................................................................1525 H-14 Machine unintentionally turns when machine travels ..................................................................................................................................1526 H-15 Wheel brakes do not work or are weak ................................................................................................................................................1527 H-16 Wheel brakes are not released or drag ...............................................................................................................................................1528 H-17 Parking brake does not work or it is weak ...........................................................................................................................................1529 H-18 Parking brake is not released or drags. .............................................................................................................................................1530 H-19 Boom does not rise ..................................................................................................................................................................1531 H-20 Boom moves slow or boom lacks lifting force .........................................................................................................................................1533 H-21 Rising boom slows down at certain height ............................................................................................................................................1535 H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground). .....................................................................................................1536 H-23 Hydraulic drift of boom is large ....................................................................................................................................................1537 H-24 Boom moves up and down during operation .............................................................................................................................................1538 H-25 Bucket does not tilt back ...........................................................................................................................................................1539 H-26 Bucket moves slow or lacks tilt-back force ..........................................................................................................................................1541 H-27 Bucket decelerates during tilt-back operation .......................................................................................................................................1543 H-28 Bucket cylinder does not hold bucket on ground ......................................................................................................................................1544 H-29 Hydraulic drift of bucket is large ..................................................................................................................................................1545 H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) .....................................................................................................1546 H-31 Boom and bucket control levers do not move smoothly and are heavy to move ...........................................................................................................1547 H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ..............................................................................................1548 H-33 Large shocks are made when work equipment starts to move and stops ..................................................................................................................1549 H-34 When certain work equipment is relieved hydraulically, other work equipment moves ...................................................................................................1550 H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ..............................................................................................................1551 H-36 Fan speed is abnormal (too high or low, or fan does not rotate) .....................................................................................................................1552 H-37 Unusual noise is heard from around fan ..............................................................................................................................................1554 Troubleshooting of engine (S-mode) ...........................................................................................................................................................1555 Information described in troubleshooting table (S mode) ..................................................................................................................................1555 S-1 Engine does not crank when starting switch is turned to START position ...............................................................................................................1556 S-2 Engine cranks but no exhaust smoke comes out .........................................................................................................................................1557 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .......................................................................................1558 S-4 Engine startability is poor ..........................................................................................................................................................1559 S-5 Engine does not pick up smoothly .....................................................................................................................................................1561 S-6 Engine stops during operation ........................................................................................................................................................1563 S-7 Engine runs rough or is unstable .....................................................................................................................................................1565 S-8 Engine lacks power ...................................................................................................................................................................1566 S-9 KDPF gets clogged in a short time ....................................................................................................................................................1568 S-10 Engine oil consumption is excessive .................................................................................................................................................1570 S-11 Engine oil becomes contaminated early ...............................................................................................................................................1571 S-12 Fuel consumption is excessive .......................................................................................................................................................1572 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....................................................................................................................1573 S-14 Oil pressure drops ..................................................................................................................................................................1574 S-15 Fuel mixes into engine oil ..........................................................................................................................................................1575 S-16 Water mixes into engine oil (milky) .................................................................................................................................................1576 S-17 Coolant temperature rises too high (overheating) ....................................................................................................................................1577 S-18 Unusual noise is heard ..............................................................................................................................................................1578 S-19 Vibration is excessive ..............................................................................................................................................................1579 S-20 Air cannot be bled from fuel circuit ................................................................................................................................................1581 S-21 Active regeneration is executed frequently ..........................................................................................................................................1582 S-22 Active regeneration takes time ......................................................................................................................................................1583 S-23 White smoke is exhausted during active regeneration .................................................................................................................................1584 50 Disassembly and assembly ......................................................................................................................................................................1585 Table of contents ............................................................................................................................................................................1586 Related information on disassembly and assembly ..............................................................................................................................................1588 How to read this manual ..................................................................................................................................................................1588 Coating materials list ...................................................................................................................................................................1590 Special tools list .......................................................................................................................................................................1594 Sketches of special tools ................................................................................................................................................................1601 Engine and cooling system ....................................................................................................................................................................1617 Removal and installation of supply pump assembly .........................................................................................................................................1617 Removal and installation of injector assembly ............................................................................................................................................1621 Removal and installation of cylinder head assembly .......................................................................................................................................1630 Removal and installation of engine hood assembly .........................................................................................................................................1637 Removal and installation of grille assembly ..............................................................................................................................................1640 Removal and installation of radiator core assembly .......................................................................................................................................1642 Removal and installation of aftercooler ..................................................................................................................................................1645 Removal and installation of hydraulic oil cooler .........................................................................................................................................1647 Removal and installation of engine assembly ..............................................................................................................................................1648 Removal and installation of engine front oil seal ........................................................................................................................................1654 Removal and installation of engine rear oil seal .........................................................................................................................................1657 Removal and installation of cooling fan and fan motor assembly ...........................................................................................................................1660 Removal and installation of KDPF assembly ................................................................................................................................................1662 Disassembly and assembly of KDPF assembly ................................................................................................................................................1666 Removal and installation of KCCV assembly ................................................................................................................................................1675 Removal and installation of air cleaner assembly .........................................................................................................................................1676 Removal and installation of KVGT assembly ................................................................................................................................................1678 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ...............................................................................................................1682 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ..............................................................................................................1684 Removal and installation of alternator belt ..............................................................................................................................................1687 Removal and installation of fuel tank assembly ...........................................................................................................................................1689 Power train ..................................................................................................................................................................................1692 Removal and installation of transfer assembly ............................................................................................................................................1692 Disassembly and assembly of transfer assembly ............................................................................................................................................1697 Disassembly and assembly of parking brake assembly .......................................................................................................................................1729 Disassembly and assembly of differential assembly ........................................................................................................................................1737 Removal and installation of front axle assembly ..........................................................................................................................................1761 Removal and installation of rear axle assembly ...........................................................................................................................................1763 Disassembly and assembly of axle housing assembly ........................................................................................................................................1766 Undercarriage and frame ......................................................................................................................................................................1775 Removal and installation of center hinge pin .............................................................................................................................................1775 Removal and installation of counterweight assembly .......................................................................................................................................1784 Hydraulic system .............................................................................................................................................................................1786 Removal and installation of hydraulic tank assembly ......................................................................................................................................1786 Removal and installation of control valve assembly .......................................................................................................................................1789 Disassembly and assembly of control valve assembly .......................................................................................................................................1793 Removal and installation of hydraulic pump assembly ......................................................................................................................................1796 Removal and installation of HST motor1 assembly ..........................................................................................................................................1800 Removal and installation of HST motor2 assembly ..........................................................................................................................................1802 Disassembly and assembly of hydraulic cylinder assembly ..................................................................................................................................1804 Work equipment ...............................................................................................................................................................................1811 Removal and installation of work equipment assembly ......................................................................................................................................1811 Cab and its attachments ......................................................................................................................................................................1817 Removal and installation of operator's cab and floor frame assembly ......................................................................................................................1817 Removal and installation of operator's cab glass (adhered glass) .........................................................................................................................1822 Removal and installation of operator's seat assembly .....................................................................................................................................1830 Removal and installation of seat belt ....................................................................................................................................................1832 Electrical system ............................................................................................................................................................................1833 Removal and installation of machine monitor assembly .....................................................................................................................................1833 Removal and installation of engine controller assembly ...................................................................................................................................1835 Removal and installation of HST controller assembly ......................................................................................................................................1837 Removal and installation of air conditioner controller assembly ..........................................................................................................................1839 Removal and installation of monitor controller assembly ..................................................................................................................................1840 Removal and installation of mass air flow and temperature sensor .........................................................................................................................1842 Removal and installation of KOMTRAX terminal assembly ....................................................................................................................................1843 Air conditioner unit .........................................................................................................................................................................1844 Removal and installation of air conditioner compressor ...................................................................................................................................1844 Removal and installation of air conditioner condenser ....................................................................................................................................1846 Removal and installation of air conditioner unit assembly ................................................................................................................................1848 60 Maintenance standard ..........................................................................................................................................................................1853 Table of contents ............................................................................................................................................................................1854 Engine and cooling system ....................................................................................................................................................................1855 Engine related parts .....................................................................................................................................................................1855 Cooling fan motor ........................................................................................................................................................................1856 Power train ..................................................................................................................................................................................1858 Damper ...................................................................................................................................................................................1858 Transfer .................................................................................................................................................................................1859 Drive shaft ..............................................................................................................................................................................1866 Axle .....................................................................................................................................................................................1867 Differential .............................................................................................................................................................................1869 Limited slip differential ................................................................................................................................................................1873 Final drive ..............................................................................................................................................................................1875 Steering system ..............................................................................................................................................................................1879 Steering column ..........................................................................................................................................................................1879 Priority valve ...........................................................................................................................................................................1880 Emergency steering valve .................................................................................................................................................................1881 Steering cylinder ........................................................................................................................................................................1882 Brake system .................................................................................................................................................................................1884 Brake accumulator charge valve ...........................................................................................................................................................1884 Slack adjuster ...........................................................................................................................................................................1885 Brake ....................................................................................................................................................................................1886 Parking brake ............................................................................................................................................................................1888 Parking brake solenoid valve .............................................................................................................................................................1889 Undercarriage and frame ......................................................................................................................................................................1890 Axle mount ...............................................................................................................................................................................1890 Center hinge pin .........................................................................................................................................................................1892 Hydraulic system .............................................................................................................................................................................1896 Hydraulic tank ...........................................................................................................................................................................1896 Double type gear pump ....................................................................................................................................................................1897 Steering and work equipment pump .........................................................................................................................................................1898 Control valve ............................................................................................................................................................................1902 Self-pressure reducing valve .............................................................................................................................................................1915 Work equipment PPC valve .................................................................................................................................................................1917 Work equipment lock solenoid valve .......................................................................................................................................................1919 Work equipment ...............................................................................................................................................................................1920 Work equipment linkage ...................................................................................................................................................................1920 Bucket ...................................................................................................................................................................................1924 Work equipment cylinder ..................................................................................................................................................................1926 Cab and its attachments ......................................................................................................................................................................1927 Cab mount ................................................................................................................................................................................1927 Electrical system ............................................................................................................................................................................1928 Bucket positioner ........................................................................................................................................................................1928 Fork positioner ..........................................................................................................................................................................1929 Remote boom positioner ...................................................................................................................................................................1930 80 Appendix ......................................................................................................................................................................................1931 Table of contents ............................................................................................................................................................................1932 Air conditioner components ...................................................................................................................................................................1933 Precautions for refrigerant ..............................................................................................................................................................1933 Air conditioner component ................................................................................................................................................................1934 Configuration and function of refrigeration cycle ........................................................................................................................................1936 Outline of refrigeration cycle ...........................................................................................................................................................1937 Air conditioner unit .....................................................................................................................................................................1939 Dual pressure switch .....................................................................................................................................................................1944 Air conditioner controller ...............................................................................................................................................................1945 Compressor ...............................................................................................................................................................................1946 Condenser ................................................................................................................................................................................1947 Receiver drier ...........................................................................................................................................................................1948 Sunlight sensor ..........................................................................................................................................................................1950 Outer temperature sensor (outside air temperature sensor) ................................................................................................................................1951 Procedure for testing and troubleshooting ................................................................................................................................................1952 Circuit diagram and arrangement of connector pins ........................................................................................................................................1954 System diagram ...........................................................................................................................................................................1957 Parts and connectors layout ..............................................................................................................................................................1960 Testing with self-diagnosis function .....................................................................................................................................................1965 How to open the electrical system abnormality record screen in service mode of the machine monitor .......................................................................................1966 Testing temperature control system .......................................................................................................................................................1968 Testing vent (mode) changeover ...........................................................................................................................................................1970 Testing FRESH/RECIRC air changeover ......................................................................................................................................................1972 Testing evaporator temperature sensor ....................................................................................................................................................1974 Testing relays ...........................................................................................................................................................................1976 Troubleshooting chart 1 ..................................................................................................................................................................1978 Troubleshooting chart 2 ..................................................................................................................................................................1979 Information in troubleshooting table .....................................................................................................................................................1981 Failure code list related to air conditioner .............................................................................................................................................1982 Failure code [879AKA] A/C Inner Sensor Open Circuit ......................................................................................................................................1983 Failure code [879AKB] A/C Inner Sensor Short Circuit .....................................................................................................................................1985 Failure code [879BKA] A/C Outer Sensor Open Circuit ......................................................................................................................................1987 Failure code [879BKB] A/C Outer Sensor Short Circuit .....................................................................................................................................1989 Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................................................................................................1991 Failure code [879CKB] Ventilating Sensor Short Circuit ...................................................................................................................................1993 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..............................................................................................................................1995 Failure code [879EMC] Ventilation Damper Abnormality .....................................................................................................................................1997 Failure code [879FMC] Air Mix Damper Abnormality .........................................................................................................................................2000 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) .....................................................................................2003 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................................................................................................2006 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...................................................................................................2009 A-4 Troubleshooting for FRESH/RECIRC air changeover ......................................................................................................................................2012 Troubleshooting with gauge pressure ......................................................................................................................................................2014 Connection of service tool ...............................................................................................................................................................2017 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ..................................................................................................2019 Handling of compressor oil ...............................................................................................................................................................2021 90 Diagrams and drawings .........................................................................................................................................................................2023 Table of contents ............................................................................................................................................................................2024 Hydraulic circuit diagram ....................................................................................................................................................................2025 Symbols in hydraulic circuit diagram .....................................................................................................................................................2025 Hydraulic circuit diagram ................................................................................................................................................................ 0 Electric circuit diagram .....................................................................................................................................................................2029 Symbols in electric circuit diagram ......................................................................................................................................................2029 Electrical circuit diagram of machine body ............................................................................................................................................... 0 Electrical circuit diagram of floor ...................................................................................................................................................... 0 Hydraulic circuit diagram.....................................................................................................................................................................2043 Electrical circuit diagram of machine body (1/4)..............................................................................................................................................2044 Electrical circuit diagram of machine body (2/4)..............................................................................................................................................2045 Electrical circuit diagram of machine body (3/4)..............................................................................................................................................2046 Electrical circuit diagram of machine body (4/4)..............................................................................................................................................2047 Electrical circuit diagram of floor (1/8).....................................................................................................................................................2048 Electrical circuit diagram of floor (2/8).....................................................................................................................................................2049 Electrical circuit diagram of floor (3/8).....................................................................................................................................................2050 Electrical circuit diagram of floor (4/8).....................................................................................................................................................2051 Electrical circuit diagram of floor (5/8).....................................................................................................................................................2052 Electrical circuit diagram of floor (6/8).....................................................................................................................................................2053 Electrical circuit diagram of floor (7/8).....................................................................................................................................................2054 Electrical circuit diagram of floor (8/8).....................................................................................................................................................2055
DESCRIPTION:
KOMATSU WA270-7 WHEEL LOADER SHOP MANUAL VENBM28500 – PDF DOWNLOAD
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 22/12/24
