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Komatsu WA320-7 Wheel Loader Shop Manual SEN06202-00 – PDF DOWNLOAD
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Komatsu WA320-7 Wheel Loader Shop Manual
SERIAL NUMBERS : 80001 and up
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Description
Komatsu WA320-7 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA320-7 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA320-7
Serial Number: 80001 and up
Book Code: SEN06202-00
Language: English
Pages: 2038
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA320-7 Wheel Loader Shop Manual
How to read the shop manual:
Composition of shop manual:
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword:
• This section includes the index, foreword, safety and basic information.
01. Specification:
• This section explains the specifications of the machine.
10. Structure and function:
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting:
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting:
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly:
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard:
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix:
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings:
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
Komatsu WA320-7 Wheel Loader Shop Manual
Cover............................................................................................................................................................................................. 1 00 Index and foreword ............................................................................................................................................................................ 3 Index ........................................................................................................................................................................................ 4 Foreword, safety and general information ..................................................................................................................................................... 19 Important safety notice .................................................................................................................................................................. 19 How to read the shop manual .............................................................................................................................................................. 26 Explanation of terms for maintenance standard ............................................................................................................................................ 28 Handling equipment of fuel system devices ................................................................................................................................................ 30 Handling of intake system parts .......................................................................................................................................................... 31 Handling of hydraulic equipment .......................................................................................................................................................... 32 Method of disconnecting and connecting of push-pull type coupler ......................................................................................................................... 34 Handling of electrical equipment ......................................................................................................................................................... 37 How to read electric wire code ........................................................................................................................................................... 45 Precautions when performing operation .................................................................................................................................................... 48 Practical use of KOMTRAX ................................................................................................................................................................. 53 Standard tightening torque table ......................................................................................................................................................... 54 List of abbreviation ..................................................................................................................................................................... 60 Conversion table ......................................................................................................................................................................... 65 01 Specification ................................................................................................................................................................................. 71 Table of contents ............................................................................................................................................................................ 72 Specifications ............................................................................................................................................................................... 73 Specification drawing .................................................................................................................................................................... 73 Specifications ........................................................................................................................................................................... 75 Weight table ............................................................................................................................................................................. 80 Table of fuel, coolant, and lubricants ................................................................................................................................................... 82 10 Structure and function ........................................................................................................................................................................ 83 Table of contents ............................................................................................................................................................................ 84 Engine and cooling system .................................................................................................................................................................... 86 Engine related parts ..................................................................................................................................................................... 86 KVGT ..................................................................................................................................................................................... 88 EGR system piping drawing ................................................................................................................................................................ 95 EGR system circuit diagram ............................................................................................................................................................... 97 EGR valve ................................................................................................................................................................................ 99 EGR cooler ............................................................................................................................................................................... 101 KCCV layout drawing ...................................................................................................................................................................... 102 KCCV ventilator .......................................................................................................................................................................... 104 KDPF ..................................................................................................................................................................................... 106 Cooling system ........................................................................................................................................................................... 110 Cooling fan motor ........................................................................................................................................................................ 112 Power train .................................................................................................................................................................................. 122 Power train system ....................................................................................................................................................................... 122 Layout of power train parts .............................................................................................................................................................. 124 Damper ................................................................................................................................................................................... 125 HST pump ................................................................................................................................................................................. 126 HST motor1 ............................................................................................................................................................................... 139 HST motor2 ............................................................................................................................................................................... 141 Transfer ................................................................................................................................................................................. 146 Clutch solenoid valve .................................................................................................................................................................... 153 Drive shaft .............................................................................................................................................................................. 155 Axle ..................................................................................................................................................................................... 156 Differential ............................................................................................................................................................................. 158 Torque proportional differential ......................................................................................................................................................... 162 Limited slip differential ................................................................................................................................................................ 164 Final drive .............................................................................................................................................................................. 169 Steering system .............................................................................................................................................................................. 171 Layout of steering devices ............................................................................................................................................................... 171 Steering column .......................................................................................................................................................................... 172 Priority valve ........................................................................................................................................................................... 173 Cushion valve ............................................................................................................................................................................ 177 Emergency steering valve ................................................................................................................................................................. 178 Orbitrol valve ........................................................................................................................................................................... 181 Brake system ................................................................................................................................................................................. 187 Layout of brake parts .................................................................................................................................................................... 187 Brake accumulator charge valve ........................................................................................................................................................... 189 Brake valve .............................................................................................................................................................................. 194 Brake accumulator ........................................................................................................................................................................ 198 Slack adjuster ........................................................................................................................................................................... 199 Brake .................................................................................................................................................................................... 201 Parking brake control .................................................................................................................................................................... 204 Parking brake ............................................................................................................................................................................ 205 Parking brake solenoid valve ............................................................................................................................................................. 206 Undercarriage and frame ...................................................................................................................................................................... 208 Axle mount ............................................................................................................................................................................... 208 Center hinge pin ......................................................................................................................................................................... 210 Tire ..................................................................................................................................................................................... 211 Hydraulic system ............................................................................................................................................................................. 213 Hydraulic component layout ............................................................................................................................................................... 213 Work equipment control ................................................................................................................................................................... 215 Hydraulic tank ........................................................................................................................................................................... 216 Double type gear pump .................................................................................................................................................................... 219 Steering and work equipment pump ......................................................................................................................................................... 220 Control valve ............................................................................................................................................................................ 232 CLSS ..................................................................................................................................................................................... 242 Hydraulic circuit diagram and names of valves ............................................................................................................................................ 246 Self-pressure reducing valve ............................................................................................................................................................. 259 Work equipment PPC valve ................................................................................................................................................................. 264 Work equipment lock solenoid valve ....................................................................................................................................................... 272 PPC circuit accumulator .................................................................................................................................................................. 273 ECSS accumulator ......................................................................................................................................................................... 274 Work equipment ............................................................................................................................................................................... 275 Work equipment linkage ................................................................................................................................................................... 275 Bucket ................................................................................................................................................................................... 276 Cab and its attachments ...................................................................................................................................................................... 277 ROPS cab ................................................................................................................................................................................. 277 Cab mount ................................................................................................................................................................................ 279 Electrical system ............................................................................................................................................................................ 280 Engine control system .................................................................................................................................................................... 280 Preheating system ........................................................................................................................................................................ 283 Engine output limit function ............................................................................................................................................................. 285 Automatic warm-up function ............................................................................................................................................................... 286 Parking brake control system ............................................................................................................................................................. 287 System operating lamp function ........................................................................................................................................................... 291 Battery disconnect switch function ....................................................................................................................................................... 292 HST controller system .................................................................................................................................................................... 294 Machine monitor system ................................................................................................................................................................... 334 Rearview monitor system .................................................................................................................................................................. 355 KOMTRAX system ........................................................................................................................................................................... 358 System component parts ................................................................................................................................................................... 361 Sensor ................................................................................................................................................................................... 384 20 Standard value tables ......................................................................................................................................................................... 405 Table of contents ............................................................................................................................................................................ 406 Standard service value table ................................................................................................................................................................. 407 Standard value table for engine .......................................................................................................................................................... 407 Standard value table for machine ......................................................................................................................................................... 409 Standard value table for electrical system ............................................................................................................................................... 421 30 Testing and adjusting ......................................................................................................................................................................... 431 Table of contents ............................................................................................................................................................................ 432 General information on testing and adjusting ................................................................................................................................................. 434 Tools for testing and adjusting .......................................................................................................................................................... 434 Sketch of tools for testing and adjusting ................................................................................................................................................ 440 Engine and cooling system .................................................................................................................................................................... 441 Testing engine speed ..................................................................................................................................................................... 441 Testing boost pressure ................................................................................................................................................................... 442 Testing exhaust gas temperature .......................................................................................................................................................... 444 Testing exhaust gas color ................................................................................................................................................................ 445 Testing and adjusting valve clearance .................................................................................................................................................... 447 Testing compression pressure ............................................................................................................................................................. 450 Testing blowby pressure .................................................................................................................................................................. 454 Testing engine oil pressure .............................................................................................................................................................. 455 Testing EGR valve and KVGT driving oil pressure .......................................................................................................................................... 456 Testing fuel pressure .................................................................................................................................................................... 457 Testing fuel discharge, return and leakage ............................................................................................................................................... 462 Bleeding air from fuel system ............................................................................................................................................................ 467 Testing fuel circuit for leakage ......................................................................................................................................................... 469 Handling cylinder cutout mode operation .................................................................................................................................................. 470 Handling no-injection cranking operation ................................................................................................................................................. 471 Testing of KDPF and muffler stack for looseness and damage ............................................................................................................................... 472 Testing of installed condition of cylinder heads and manifolds ........................................................................................................................... 473 Testing engine piping for damage and looseness ........................................................................................................................................... 474 Testing and adjusting air conditioner compressor belt tension ............................................................................................................................ 475 Replacing alternator belt ................................................................................................................................................................ 476 Power train .................................................................................................................................................................................. 477 Testing oil leakage from axle final drive ................................................................................................................................................ 477 Testing drive shaft for looseness, backlash, and damage .................................................................................................................................. 478 Testing accelerator pedal ................................................................................................................................................................ 479 Testing and adjusting HST oil pressure ................................................................................................................................................... 480 Testing transfer clutch control pressure ................................................................................................................................................. 483 Steering system .............................................................................................................................................................................. 484 Testing directional lever ................................................................................................................................................................ 484 Testing steering wheel ................................................................................................................................................................... 485 Testing work equipment control lever ..................................................................................................................................................... 487 Testing and adjusting steering circuit oil pressure ...................................................................................................................................... 489 Bleeding air from steering cylinder circuit .............................................................................................................................................. 491 Brake system ................................................................................................................................................................................. 492 Testing brake pedal ...................................................................................................................................................................... 492 Testing braking performance .............................................................................................................................................................. 493 Testing and adjusting of accumulator charge pressure ..................................................................................................................................... 494 Testing wheel brake oil pressure ......................................................................................................................................................... 496 Testing lowering of wheel brake pressure ................................................................................................................................................. 497 Testing wear of wheel brake disc ......................................................................................................................................................... 499 Bleeding air from wheel brake circuit .................................................................................................................................................... 500 Releasing remaining pressure in brake accumulator circuit ................................................................................................................................ 501 Testing parking brake performance ........................................................................................................................................................ 502 Testing wear of parking brake disc ....................................................................................................................................................... 503 Testing parking brake release pressure ................................................................................................................................................... 504 Method of releasing parking brake manually ............................................................................................................................................... 505 Hydraulic system ............................................................................................................................................................................. 506 Testing fan speed ........................................................................................................................................................................ 506 Testing fan circuit oil pressure ......................................................................................................................................................... 507 Bleeding air from hydraulic fan circuit .................................................................................................................................................. 509 Testing and adjusting work equipment PPC oil pressure .................................................................................................................................... 510 Testing and adjusting work equipment oil pressure ........................................................................................................................................ 512 Bleeding air from work equipment circuit ................................................................................................................................................. 516 Releasing remaining pressure from work equipment circuit ................................................................................................................................. 517 Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas .................................................................................. 519 Work equipment ............................................................................................................................................................................... 523 Testing and adjusting bucket positioner and bucket proximity switch ...................................................................................................................... 523 Testing and adjusting boom position detection lever ...................................................................................................................................... 525 Electrical system ............................................................................................................................................................................ 526 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ................................................................................................... 526 Special functions of machine monitor ..................................................................................................................................................... 527 Angle adjustment of rear view camera ..................................................................................................................................................... 605 Handling voltage circuit of engine controller ............................................................................................................................................ 606 Handling battery disconnect switch ....................................................................................................................................................... 607 Testing diodes ........................................................................................................................................................................... 608 Pm clinic .................................................................................................................................................................................... 609 Pm Clinic service ........................................................................................................................................................................ 609 Check sheet .............................................................................................................................................................................. 610 40 Troubleshooting ............................................................................................................................................................................... 615 Table of contents ............................................................................................................................................................................ 616 General information on troubleshooting ....................................................................................................................................................... 625 Troubleshooting points ................................................................................................................................................................... 625 Sequence of events in troubleshooting .................................................................................................................................................... 627 Checks before troubleshooting ............................................................................................................................................................ 629 Inspection procedure before troubleshooting .............................................................................................................................................. 631 Preparation for troubleshooting of electrical system ..................................................................................................................................... 648 Classification and procedures for troubleshooting ........................................................................................................................................ 654 Symptom and troubleshooting numbers ...................................................................................................................................................... 657 Information in troubleshooting table ..................................................................................................................................................... 660 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit .................................................................................................. 662 Connector list and layout ................................................................................................................................................................ 665 Connector contact identification ......................................................................................................................................................... 679 T-branch box and T-branch adapter table .................................................................................................................................................. 717 Fuse location table ...................................................................................................................................................................... 722 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ............................................................................................................................ 725 Precautions when performing troubleshooting of machine monitor ........................................................................................................................... 728 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit .................................................................................................. 730 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .......................................................................................................... 735 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) .............................................................................................. 736 Failure codes table ...................................................................................................................................................................... 737 Troubleshooting by failure code (Display of code) ............................................................................................................................................ 749 Failure code [2F00MA] Failure of Parking Brake Circuit ................................................................................................................................... 749 Failure code [2F00MB] Malfunction of Parking Brake ....................................................................................................................................... 752 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................................................................................................... 754 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ................................................................................................................................ 756 Failure code [6091NX] HST Oil Filter Clogging ............................................................................................................................................ 758 Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ......................................................................................................................... 760 Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. .......................................................................................................................... 762 Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ............................................................................................................................. 764 Failure code [879AKA] A/C Inner Sensor Open Circuit ...................................................................................................................................... 766 Failure code [879AKB] A/C Inner Sensor Short Circuit ..................................................................................................................................... 767 Failure code [879BKA] A/C Outer Sensor Open Circuit ...................................................................................................................................... 768 Failure code [879BKB] A/C Outer Sensor Short Circuit ..................................................................................................................................... 769 Failure code [879CKA] Ventilating Sensor Open Circuit .................................................................................................................................... 770 Failure code [879CKB] Ventilating Sensor Short Circuit ................................................................................................................................... 771 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................................................................................................. 772 Failure code [879EMC] Ventilation Damper Abnormality ..................................................................................................................................... 773 Failure code [879FMC] Air Mix Damper Abnormality ......................................................................................................................................... 774 Failure code [989L00] Engine Controller Lock Caution 1 ................................................................................................................................... 775 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................................................................................... 776 Failure code [989N00] Engine Controller Lock Caution 3 ................................................................................................................................... 777 Failure code [A1U0N3] HC Desorb Request 1 ................................................................................................................................................ 778 Failure code [A1U0N4] HC Desorb Request 2 ................................................................................................................................................ 780 Failure code [AA10NX] Air Cleaner Clogging ............................................................................................................................................... 782 Failure code [B@BAZG] Eng Oil Press Low .................................................................................................................................................. 784 Failure code [B@BAZK] Engine Oil Level Low ............................................................................................................................................... 785 Failure code [B@BCNS] Eng Water Overheat ................................................................................................................................................. 787 Failure code [B@BCZK] Eng Water Level Low ................................................................................................................................................ 788 Failure code [B@CRNS] HST Oil Temp. Overheat ............................................................................................................................................. 790 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................................................................................................... 791 Failure code [CA122] Chg Air Press Sensor High Error ..................................................................................................................................... 792 Failure code [CA123] Chg Air Press Sensor Low Error ...................................................................................................................................... 794 Failure code [CA131] Throttle Sensor High Error .......................................................................................................................................... 796 Failure code [CA132] Throttle Sensor Low Error ........................................................................................................................................... 798 Failure code [CA144] Coolant Temp Sens High Error ........................................................................................................................................ 800 Failure code [CA145] Coolant Temp Sens Low Error ......................................................................................................................................... 802 Failure code [CA153] Chg Air Temp Sensor High Error ...................................................................................................................................... 804 Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................................................................................................... 806 Failure code [CA187] Sensor 2 Supply Volt Low Error ...................................................................................................................................... 808 Failure code [CA221] Ambient Press Sensor High Error ..................................................................................................................................... 810 Failure code [CA222] Ambient Press Sensor Low Error ...................................................................................................................................... 812 Failure code [CA227] Sensor 2 Supply Volt High Error ..................................................................................................................................... 814 Failure code [CA234] Eng Overspeed ....................................................................................................................................................... 815 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................................................................................................... 816 Failure code [CA239] Ne Speed Sens Supply Volt High Error ................................................................................................................................ 817 Failure code [CA271] IMV/PCV1 Short Error ................................................................................................................................................ 818 Failure code [CA272] IMV/PCV1 Open Error ................................................................................................................................................. 820 Failure code [CA295] Ambient Press Sens In Range Error ................................................................................................................................... 822 Failure code [CA322] Inj #1(L#1) Open/Short Error ........................................................................................................................................ 823 Failure code [CA323] Inj #5(L#5) Open/Short Error ........................................................................................................................................ 825 Failure code [CA324] Inj #3(L#3) Open/Short Error ........................................................................................................................................ 827 Failure code [CA325] Inj #6(L#6) Open/Short Error ........................................................................................................................................ 829 Failure code [CA331] Inj #2(L#2) Open/Short Error ........................................................................................................................................ 831 Failure code [CA332] Inj #4(L#4) Open/Short Error ........................................................................................................................................ 833 Failure code [CA343] ECM Critical Internal Failure ....................................................................................................................................... 835 Failure code [CA351] Injectors Drive Circuit Error ....................................................................................................................................... 836 Failure code [CA352] Sensor 1 Supply Volt Low Error ...................................................................................................................................... 837 Failure code [CA356] Mass Air Flow Sensor High Error ..................................................................................................................................... 839 Failure code [CA357] Mass Air Flow Sensor Low Error ...................................................................................................................................... 841 Failure code [CA386] Sensor 1 Supply Volt High Error ..................................................................................................................................... 843 Failure code [CA428] Water in Fuel Sensor High Error ..................................................................................................................................... 844 Failure code [CA429] Water in Fuel Sensor Low Error ...................................................................................................................................... 846 Failure code [CA431] Idle Validation Sw Error ............................................................................................................................................ 848 Failure code [CA432] Idle Validation Process Error ....................................................................................................................................... 851 Failure code [CA435] Eng Oil Press Sw Error .............................................................................................................................................. 854 Failure code [CA441] Battery Voltage Low Error ........................................................................................................................................... 855 Failure code [CA442] Battery Voltage High Error .......................................................................................................................................... 857 Failure code [CA449] Rail Press Very High Error .......................................................................................................................................... 858 Failure code [CA451] Rail Press Sensor High Error ........................................................................................................................................ 859 Failure code [CA452] Rail Press Sensor Low Error ......................................................................................................................................... 861 Failure code [CA488] Chg Air Temp High Torque Derate ..................................................................................................................................... 863 Failure code [CA515] Rail Press Sens Sup Volt High Error ................................................................................................................................. 864 Failure code [CA516] Rail Press Sens Sup Volt Low Error .................................................................................................................................. 866 Failure code [CA553] Rail Press High Error ............................................................................................................................................... 868 Failure code [CA555] Crankcase Press High Error 1 ........................................................................................................................................ 869 Failure code [CA556] Crankcase Press High Error 2 ........................................................................................................................................ 870 Failure code [CA559] Rail Press Low Error ................................................................................................................................................ 871 Failure code [CA595] Turbo Speed High Error 2 ............................................................................................................................................ 873 Failure code [CA687] Turbo Speed Low Error ............................................................................................................................................... 874 Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................................................................................... 876 Failure code [CA691] Intake Air Temp Sens High Error ..................................................................................................................................... 878 Failure code [CA692] Intake Air Temp Sens Low Error ...................................................................................................................................... 880 Failure code [CA697] ECM Internal Temp Sensor High Error ................................................................................................................................. 882 Failure code [CA698] ECM Int Temp Sensor Low Error ....................................................................................................................................... 883 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..................................................................................................................................... 884 Failure code [CA778] Eng Bkup Speed Sensor Error ......................................................................................................................................... 886 Failure code [CA1117] Persistent Data Lost Error ......................................................................................................................................... 891 Failure code [CA1664] KDOC Malfunction ................................................................................................................................................... 892 Failure code [CA1691] Regeneration Ineffective ........................................................................................................................................... 895 Failure code [CA1695] Sensor 5 Supply Volt High Error .................................................................................................................................... 898 Failure code [CA1696] Sensor 5 Supply Volt Low Error ..................................................................................................................................... 899 Failure code [CA1843] Crankcase Press Sens High Error .................................................................................................................................... 901 Failure code [CA1844] Crankcase Press Sens Low Error ..................................................................................................................................... 903 Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................................................................................................... 905 Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................................................................................................... 907 Failure code [CA1883] KDPF Delta P Sens In Range Error ................................................................................................................................... 909 Failure code [CA1921] KDPF Soot Load High Error 1 ........................................................................................................................................ 913 Failure code [CA1922] KDPF Soot Load High Error 2 ........................................................................................................................................ 916 Failure code [CA1942] Crankcase Press Sens In Range Error ................................................................................................................................ 921 Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................................................................................................... 922 Failure code [CA2185] Throt Sensor Sup Volt High Error ................................................................................................................................... 925 Failure code [CA2186] Throt Sensor Sup Volt Low Error .................................................................................................................................... 927 Failure code [CA2249] Rail Press Very Low Error .......................................................................................................................................... 929 Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................................................................................................... 930 Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................................................................................................... 932 Failure code [CA2288] Turbo Speed High Error 1 ........................................................................................................................................... 935 Failure code [CA2311] IMV Solenoid Error ................................................................................................................................................. 936 Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................................................................................................... 937 Failure code [CA2353] EGR Valve Solenoid Short Error ..................................................................................................................................... 939 Failure code [CA2357] EGR Valve Servo Error .............................................................................................................................................. 941 Failure code [CA2373] Exhaust Manifold Press Sens High error ............................................................................................................................. 942 Failure code [CA2374] Exhaust Manifold Press Sens Low error .............................................................................................................................. 944 Failure code [CA2375] EGR Orifice Temp Sens High Error ................................................................................................................................... 946 Failure code [CA2376] EGR Orifice Temp Sens Low Error .................................................................................................................................... 948 Failure code [CA2381] KVGT Pos Sens High Error ........................................................................................................................................... 950 Failure code [CA2382] KVGT Pos Sens Low Error ............................................................................................................................................ 952 Failure code [CA2383] KVGT Solenoid Open Error ........................................................................................................................................... 955 Failure code [CA2386] KVGT Solenoid Short Error .......................................................................................................................................... 957 Failure code [CA2387] KVGT Servo Error ................................................................................................................................................... 959 Failure code [CA2554] Exh Manifold Press Sens In Range Error ............................................................................................................................. 960 Failure code [CA2555] Grid Htr Relay Volt Low Error ...................................................................................................................................... 961 Failure code [CA2556] Grid Htr Relay Volt High Error ..................................................................................................................................... 963 Failure code [CA2637] KDOC Face Plugging ................................................................................................................................................. 965 Failure code [CA2639] Manual Stationary Regeneration Request ............................................................................................................................. 967 Failure code [CA2961] EGR Orifice Temp High Error 1 ...................................................................................................................................... 970 Failure code [CA2973] Chg Air Press Sensor In Range Error ................................................................................................................................ 971 Failure code [CA3133] KDPF Outlet Press Sens High Error .................................................................................................................................. 972 Failure code [CA3134] KDPF Outlet Press Sens Low Error ................................................................................................................................... 974 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .............................................................................................................................. 976 Failure code [CA3251] KDOC Inlet Temp High Error ......................................................................................................................................... 980 Failure code [CA3253] KDOC Temp Error - Non Regeneration ................................................................................................................................. 983 Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................................................................................................... 986 Failure code [CA3255] KDPF Temp Error - Non Regeneration ................................................................................................................................. 989 Failure code [CA3256] KDPF Outlet Temp High Error 1 ...................................................................................................................................... 992 Failure code [CA3311] KDOC Outlet Temp High Error 2 ...................................................................................................................................... 995 Failure code [CA3312] KDPF Outlet Temp High Error 2 ...................................................................................................................................... 998 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...................................................................................................................................1001 Failure code [CA3314] KDOC Inlet Temp Sens High Error ....................................................................................................................................1004 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ................................................................................................................................1007 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....................................................................................................................................1011 Failure code [CA3317] KDOC Outlet Temp Sens High Error ...................................................................................................................................1014 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...............................................................................................................................1017 Failure code [CA3319] KDPF Outlet Temp Sens High Error ...................................................................................................................................1021 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....................................................................................................................................1024 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...............................................................................................................................1027 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...........................................................................................................................1031 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ............................................................................................................................1033 Failure code [CA3741] Rail Press Valve Trip Error ........................................................................................................................................1035 Failure code [D110L4] Disconnection of Battery Relay Signal ..............................................................................................................................1036 Failure code [D160KA] Disconnection of Backup Lamp Relay Output ..........................................................................................................................1038 Failure code [D160KY] Hot Short of Backup Lamp Relay Output ..............................................................................................................................1040 Failure code [D191KA] Disconnection of Neutral Output Relay ..............................................................................................................................1042 Failure code [D191KB] Ground Fault of Neutral Output Relay ...............................................................................................................................1044 Failure code [D191KY] Hot Short of Neutral Output Relay ..................................................................................................................................1046 Failure code [D192KA] Disconnection of ECSS Solenoid .....................................................................................................................................1048 Failure code [D192KB] Ground Fault of ECSS Solenoid ......................................................................................................................................1050 Failure code [D192KY] Hot Short of ECSS Solenoid .........................................................................................................................................1051 Failure code [D19JKZ] Personal Code Relay Abnormality ....................................................................................................................................1052 Failure code [D1B0KA] Disconnection of HST Safety Relay ..................................................................................................................................1054 Failure code [D1B0KB] Ground Fault of HST Safety Relay ...................................................................................................................................1056 Failure code [D1B0KY] Hot Short of HST Safety Relay ......................................................................................................................................1058 Failure code [D1B0MC] Malfunction of HST Safety Relay ....................................................................................................................................1060 Failure code [D1E6KA] Disconnection of Parking Brake Relay ...............................................................................................................................1061 Failure code [D1E6KB] Ground Fault of Parking Brake Relay ................................................................................................................................1063 Failure code [D1E6KY] Hot Short of Parking Brake Relay ...................................................................................................................................1065 Failure code [D5ZHKA] Failure of Key SW C Signal .........................................................................................................................................1067 Failure code [D5ZHKB] Key SW C Signal Short Circuit ......................................................................................................................................1069 Failure code [D5ZHL6] Disconnection of Key SW C ..........................................................................................................................................1071 Failure code [D811MC] KOMTRAX Error ......................................................................................................................................................1072 Failure code [D862KA] GPS Antenna Open Circuit ...........................................................................................................................................1073 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ..............................................................................................................................1074 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .............................................................................................................................1076 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ............................................................................................................................................1078 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..............................................................................................................................................1079 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...........................................................................................................................1081 Failure code [DAF0MB] Monitor ROM Abnormality ............................................................................................................................................1082 Failure code [DAF0MC] Monitor Error ......................................................................................................................................................1083 Failure code [DAF3KK] Controller Power Source Low (MON) ..................................................................................................................................1084 Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................................................................................................1086 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .............................................................................................................................1087 Failure code [DAFGMC] GPS Module Error ...................................................................................................................................................1088 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ..................................................................................................................................1089 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) .................................................................................................................................1091 Failure code [DAFQKR] CAN2 Discon (Monitor) ..............................................................................................................................................1093 Failure code [DAJ0KK] Controller Power Source Low (HST) ..................................................................................................................................1094 Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ...........................................................................................................................1097 Failure code [DAJ0MC] HST Con Error ......................................................................................................................................................1098 Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ..................................................................................................................................1099 Failure code [DAJ2KK] Solenoid Power Source Low (HST) ....................................................................................................................................1101 Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ............................................................................................................................1104 Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay .................................................................................................................................1106 Failure code [DAJ5KX] Failure of 5V Power Source 0 .......................................................................................................................................1108 Failure code [DAJ6KX] Failure of 5V Power Source 1 .......................................................................................................................................1110 Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) .............................................................................................................................1112 Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ..................................................................................................................................1113 Failure code [DAJLKB] Operating Lamp Short Circuit (HST) .................................................................................................................................1115 Failure code [DAJQKR] CAN2 Discon ( HST Con) .............................................................................................................................................1117 Failure code [DAJRKR] CAN1 Discon ( HST Con) .............................................................................................................................................1118 Failure code [DAJRMA] Inconsistency of Option Selection (HST) ............................................................................................................................1119 Failure code [DAZ9KQ] A/C Model Selection Abnormality ....................................................................................................................................1120 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...........................................................................................................................................1121 Failure code [DB2QKR] CAN2 Discon (Engine Con) ...........................................................................................................................................1122 Failure code [DB2RKR] CAN1 Discon (Engine Con) ...........................................................................................................................................1127 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...........................................................................................................................1131 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch .........................................................................................................................1133 Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ................................................................................................................................1135 Failure code [DDB6L4] Parking Brake Signal Malfunction ...................................................................................................................................1137 Failure code [DDD7KA] Failure of Variable Speed Control ..................................................................................................................................1140 Failure code [DDD7KY] Hot Short of Variable Speed Control ................................................................................................................................1142 Failure code [DDK3KA] FNR SW Input Signal Disconnection ..................................................................................................................................1144 Failure code [DDK3KB] FNR SW Input Signal Short Circuit ..................................................................................................................................1146 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...............................................................................................................................1148 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...............................................................................................................................1151 Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ............................................................................................................................1153 Failure code [DF10KA] Disconnection of Speed Range Input .................................................................................................................................1155 Failure code [DF10KB] Ground Fault of Speed Range Input ..................................................................................................................................1158 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor .............................................................................................................................1161 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ..................................................................................................................................1163 Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ..............................................................................................................................1165 Failure code [DHG1KX] Out of Range of HST Oil Temp. Sensor ...............................................................................................................................1167 Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ...........................................................................................................................1169 Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) .........................................................................................................................1171 Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ...........................................................................................................................1173 Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) .........................................................................................................................1175 Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) .............................................................................................................................1177 Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ...........................................................................................................................1179 Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ...........................................................................................................................1181 Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. .........................................................................................................................1183 Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ............................................................................................................................1185 Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ..........................................................................................................................1187 Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ............................................................................................................................1189 Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ..........................................................................................................................1191 Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ...........................................................................................................................1193 Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit .........................................................................................................................1195 Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ...........................................................................................................................1197 Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit .........................................................................................................................1199 Failure code [DHT8ZG] Steering Oil Pressure Low ..........................................................................................................................................1201 Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ...........................................................................................................................1202 Failure code [DJF1KA] Disconnection of Fuel Level Sensor .................................................................................................................................1204 Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................................................................................................1206 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ............................................................................................................................1209 Failure code [DK55L5] Failure of FNR Lever Potentio ......................................................................................................................................1211 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...............................................................................................................................1212 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) .............................................................................................................................1215 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...........................................................................................................................1218 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ................................................................................................................................1221 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ..............................................................................................................................1224 Failure code [DK70KA] Failure of inching sensor Circuit ..................................................................................................................................1227 Failure code [DK70KY] Hot Short of inching sensor Circuit ................................................................................................................................1230 Failure code [DKA0KA] Failure of Boom Angle Sensor .......................................................................................................................................1232 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .............................................................................................................................1234 Failure code [DKA0L0] Boom Angle Sensor Dislocation ......................................................................................................................................1236 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor .........................................................................................................................1238 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...............................................................................................................................1240 Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ...........................................................................................................................1242 Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ...........................................................................................................................1244 Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ...............................................................................................................................1246 Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ..............................................................................................................................1249 Failure code [DPQ1KR] LIN Discon (Switch Panel) ..........................................................................................................................................1251 Failure code [DPQ2KR] LIN Discon (LED Unit) ..............................................................................................................................................1254 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) .....................................................................................................................................1257 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...........................................................................................................................................1260 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ............................................................................................................................1262 Failure code [DV00KB] Ground Fault of Buzzer Output ......................................................................................................................................1264 Failure code [DW26KA] Disconnection of Motor 2 Solenoid ..................................................................................................................................1266 Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ...................................................................................................................................1268 Failure code [DW26KY] Hot Short of Motor 2 Solenoid ......................................................................................................................................1270 Failure code [DW4BKA] Disconnection of Parking Brake Valve ...............................................................................................................................1271 Failure code [DW4BKB] Ground Fault of Parking Brake Valve ................................................................................................................................1273 Failure code [DW4BKY] Hot Short of Parking Brake Valve ...................................................................................................................................1275 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ............................................................................................................................1276 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .........................................................................................................................1278 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ............................................................................................................................1280 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid .............................................................................................................................1281 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ..............................................................................................................................1283 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid .................................................................................................................................1285 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ............................................................................................................................1286 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) .............................................................................................................................1288 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ................................................................................................................................1290 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..........................................................................................................................1292 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...........................................................................................................................1294 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ..............................................................................................................................1296 Failure code [DX19KA] Disconnection of Motor 1 Solenoid ..................................................................................................................................1297 Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ...................................................................................................................................1299 Failure code [DX19KY] Hot Short of Motor 1 Solenoid ......................................................................................................................................1301 Failure code [DX20KA] Disconnection of Clutch Control Solenoid ...........................................................................................................................1303 Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ............................................................................................................................1305 Failure code [DX20KY] Hot Short of Clutch Control Solenoid ...............................................................................................................................1307 Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. .................................................................................................................................1309 Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ..................................................................................................................................1311 Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. .....................................................................................................................................1313 Failure code [DXH7KA] Disconnection of Reverse Solenoid ..................................................................................................................................1315 Failure code [DXH7KB] Ground Fault of Reverse Solenoid ...................................................................................................................................1317 Failure code [DXH7KY] Hot Short of Reverse Solenoid ......................................................................................................................................1319 Failure code [DXH8KA] Disconnection of Forward Solenoid ..................................................................................................................................1321 Failure code [DXH8KB] Ground Fault of Forward Solenoid ...................................................................................................................................1323 Failure code [DXH8KY] Hot Short of Forward Solenoid ......................................................................................................................................1325 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ............................................................................................................................1327 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) .............................................................................................................................1329 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ................................................................................................................................1331 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ............................................................................................................................1332 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) .............................................................................................................................1334 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ................................................................................................................................1336 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...............................................................................................................................1337 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal .............................................................................................................................1340 Failure code [J141N1] Steering Pump Over Run .............................................................................................................................................1342 Failure code [LA00L3] Failure of Fan Reverse .............................................................................................................................................1343 Failure code [M100N1] HST Pump Over Run ..................................................................................................................................................1344 Failure code [M400N1] HST Motor 1 Over Run ...............................................................................................................................................1345 Troubleshooting of electrical system (E-mode) ................................................................................................................................................1346 E-1 Engine does not start ................................................................................................................................................................1346 E-2 Manual preheating system does not work ...............................................................................................................................................1353 E-3 Automatic preheating system does not work ............................................................................................................................................1356 E-4 While preheating is working, preheating monitor does not light up ....................................................................................................................1358 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .........................................................................................................1360 E-6 LCD unit on machine monitor displays nothing .........................................................................................................................................1363 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ................................................................................................1365 E-8 LCD on machine monitor does not display properly .....................................................................................................................................1367 E-9 Meter unit display on machine monitor is abnormal ....................................................................................................................................1369 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ....................................................................................................................1372 E-11 Caution LED on machine monitor is abnormal ..........................................................................................................................................1375 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ............................................................................................1377 E-13 Two switches operation of switch panel on machine monitor does not function .........................................................................................................1379 E-14 Switch panel buzzer of machine monitor is abnormal ..................................................................................................................................1382 E-15 Rearview monitor does not light up or backlight flickers ............................................................................................................................1384 E-16 Rearview monitor images are not displayed clearly ...................................................................................................................................1387 E-17 Rearview monitor brightness cannot be adjusted ......................................................................................................................................1390 E-18 Night lighting lamp of rearview monitor is abnormal .................................................................................................................................1393 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ................................................................................................1395 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ..................................................................................1396 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light .......................................................................................1400 E-22 Air cleaner clogging indicator lamp does not light ..................................................................................................................................1402 E-23 Radiator coolant level caution lamp does not light ..................................................................................................................................1404 E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light .......................................................................1406 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 ....1407 E-26 Fuel level gauge does not indicate correct level ....................................................................................................................................1409 E-27 Seat belt caution lamp indication is abnormal .......................................................................................................................................1411 E-28 Horn does not sound .................................................................................................................................................................1412 E-29 Horn does not stop sounding .........................................................................................................................................................1415 E-30 Alarm buzzer does not sound .........................................................................................................................................................1417 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding .........................................................................................................1419 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 ................1420 E-33 Setting does not change while operating traction control switch .....................................................................................................................1422 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 .......................................................1424 E-35 Remote positioner does not work or cannot be released ...............................................................................................................................1427 E-36 Bucket positioner does not work or cannot be released ...............................................................................................................................1429 E-37 Direction selector (FNR) switch mode is not selected or not released ................................................................................................................1432 E-38 PZ auto tilt-in does not work .......................................................................................................................................................1434 E-39 Tracktion level does not display MAX when max traction switch is turned ON ..........................................................................................................1437 E-40 ECSS function cannot be selected or cannot be released ..............................................................................................................................1439 E-41 None of headlamp, clearance lamp, and tail lamp lights ..............................................................................................................................1441 E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out ..........................................................................................................1443 E-43 Both High and Low beams of headlamp do not light up or go out .......................................................................................................................1447 E-44 Low beam of headlamp does not light up or go out ....................................................................................................................................1451 E-45 High beam of headlamp does not light up or go out ...................................................................................................................................1453 E-46 Front working lamp does not light up or go out ......................................................................................................................................1455 E-47 Rear working lamp does not light up or go out .......................................................................................................................................1459 E-48 All of turn signal lamps and hazard lamps do not flash or go out ....................................................................................................................1463 E-49 Turn signal lamps do not flash or go out ............................................................................................................................................1466 E-50 Hazard lamp does not flash or go out ................................................................................................................................................1469 E-51 Brake lamp does not light or stays lighted ..........................................................................................................................................1472 E-52 Backup lamp does not light up or does not go out ....................................................................................................................................1475 E-53 Backup buzzer does not sound or continues to sound ..................................................................................................................................1478 E-54 Front wiper does not operate ........................................................................................................................................................1480 E-55 Rear wiper does not operate .........................................................................................................................................................1483 E-56 Window washer does not operate ......................................................................................................................................................1485 E-57 KOMTRAX system does not operate normally ............................................................................................................................................1488 Troubleshooting of hydraulic and mechanical system (H-mode) ..................................................................................................................................1490 Information described in troubleshooting table (H-mode) ..................................................................................................................................1490 System chart of hydraulic and mechanical systems .........................................................................................................................................1491 Failure mode and cause table .............................................................................................................................................................1493 H-1 Machine does not travel forward or backward ..........................................................................................................................................1500 H-2 Machine does not travel forward (Machine travels backward normally) ..................................................................................................................1503 H-3 Machine does not travel backward (Machine travels forward normally) ..................................................................................................................1504 H-4 Machine does not travel forward or backward fast .....................................................................................................................................1505 H-5 Machine does not travel forward fast (Machine travel backward fast) ..................................................................................................................1509 H-6 Machine does not travel backward fast (Machine travel forward fast) ..................................................................................................................1510 H-7 Machine lacks power neither when traveling forward nor backward ......................................................................................................................1511 H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ....................................................................................1514 H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ...................................................................................1515 H-10 Engine stalls during travel or engine speed drops significantly .....................................................................................................................1516 H-11 Steering wheel is too heavy to turn .................................................................................................................................................1517 H-12 Steering wheel is heavy to turn .....................................................................................................................................................1519 H-13 Machine sways or large shocks are made while machine turns ..........................................................................................................................1520 H-14 Machine unintentionally turns when machine travels ..................................................................................................................................1521 H-15 Wheel brakes do not work or are weak ................................................................................................................................................1522 H-16 Wheel brakes are not released or drag ...............................................................................................................................................1523 H-17 Parking brake does not work or it is weak ...........................................................................................................................................1524 H-18 Parking brake is not released or drags. .............................................................................................................................................1525 H-19 Boom does not rise ..................................................................................................................................................................1526 H-20 Boom moves slow or boom lacks lifting force .........................................................................................................................................1528 H-21 Rising boom slows down at certain height ............................................................................................................................................1530 H-22 Lift cylinders do not serve to hold bucket (bucket rises off ground) ................................................................................................................1531 H-23 Hydraulic drift of boom is large ....................................................................................................................................................1532 H-24 Boom moves up and down during operation .............................................................................................................................................1533 H-25 Bucket does not tilt back ...........................................................................................................................................................1534 H-26 Bucket moves slow or lacks tilt-back force ..........................................................................................................................................1536 H-27 Bucket decelerates during tilt-back operation .......................................................................................................................................1538 H-28 Bucket cylinder does not hold bucket on ground ......................................................................................................................................1539 H-29 Hydraulic drift of bucket is large ..................................................................................................................................................1540 H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) .....................................................................................................1541 H-31 Boom and bucket control levers do not move smoothly and are heavy to move ...........................................................................................................1542 H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ..............................................................................................1543 H-33 Large shocks are made when work equipment starts to move and stops ..................................................................................................................1544 H-34 When certain work equipment is relieved hydraulically, other work equipment moves ...................................................................................................1545 H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ..............................................................................................................1546 H-36 Fan speed is abnormal (too high or low, or fan does not rotate) .....................................................................................................................1547 H-37 Unusual noise is heard from around fan ..............................................................................................................................................1549 Troubleshooting of engine (S-mode) ...........................................................................................................................................................1550 Information described in troubleshooting table (S mode) ..................................................................................................................................1550 S-1 Engine does not crank when starting switch is turned to START position ...............................................................................................................1551 S-2 Engine cranks but no exhaust smoke comes out .........................................................................................................................................1552 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .......................................................................................1553 S-4 Engine startability is poor ..........................................................................................................................................................1554 S-5 Engine does not pick up smoothly .....................................................................................................................................................1556 S-6 Engine stops during operation ........................................................................................................................................................1558 S-7 Engine runs rough or is unstable .....................................................................................................................................................1560 S-8 Engine lacks power ...................................................................................................................................................................1561 S-9 KDPF gets clogged in a short time ....................................................................................................................................................1563 S-10 Engine oil consumption is excessive .................................................................................................................................................1565 S-11 Engine oil becomes contaminated early ...............................................................................................................................................1566 S-12 Fuel consumption is excessive .......................................................................................................................................................1567 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....................................................................................................................1568 S-14 Oil pressure drops ..................................................................................................................................................................1569 S-15 Fuel mixes into engine oil ..........................................................................................................................................................1570 S-16 Water mixes into engine oil (milky) .................................................................................................................................................1571 S-17 Coolant temperature rises too high (overheating) ....................................................................................................................................1572 S-18 Unusual noise is heard ..............................................................................................................................................................1573 S-19 Vibration is excessive ..............................................................................................................................................................1574 S-20 Air cannot be bled from fuel circuit ................................................................................................................................................1576 S-21 Active regeneration is executed frequently ..........................................................................................................................................1577 S-22 Active regeneration takes time ......................................................................................................................................................1578 S-23 White smoke is exhausted during active regeneration .................................................................................................................................1579 50 Disassembly and assembly ......................................................................................................................................................................1581 Table of contents ............................................................................................................................................................................1582 General information on disassembly and assembly ..............................................................................................................................................1584 How to read this manual ..................................................................................................................................................................1584 Coating materials list ...................................................................................................................................................................1586 Special tools list .......................................................................................................................................................................1590 Sketches of special tools ................................................................................................................................................................1595 Engine and cooling system ....................................................................................................................................................................1608 Removal and installation of supply pump assembly .........................................................................................................................................1608 Removal and installation of injector assembly ............................................................................................................................................1611 Removal and installation of cylinder head assembly .......................................................................................................................................1620 Removal and installation of engine hood assembly .........................................................................................................................................1633 Removal and installation of radiator core assembly .......................................................................................................................................1635 Removal and installation of aftercooler ..................................................................................................................................................1637 Removal and installation of hydraulic oil cooler .........................................................................................................................................1638 Removal and installation of engine assembly ..............................................................................................................................................1639 Removal and installation of engine front oil seal ........................................................................................................................................1647 Removal and installation of engine rear oil seal .........................................................................................................................................1650 Removal and installation of cooling fan and fan motor assembly ...........................................................................................................................1653 Removal and installation of KDPF assembly ................................................................................................................................................1655 Disassembly and assembly of KDPF assembly ................................................................................................................................................1658 Removal and installation of KCCV assembly ................................................................................................................................................1667 Removal and installation of air cleaner assembly .........................................................................................................................................1668 Removal and installation of KVGT assembly ................................................................................................................................................1669 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ...............................................................................................................1672 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ..............................................................................................................1673 Removal and installation of alternator belt ..............................................................................................................................................1675 Removal and installation of fuel tank assembly ...........................................................................................................................................1676 Power train ..................................................................................................................................................................................1679 Removal and installation of transfer assembly ............................................................................................................................................1679 Disassembly and assembly of transfer assembly ............................................................................................................................................1683 Removal and installation of front axle assembly ..........................................................................................................................................1714 Removal and installation of rear axle assembly ...........................................................................................................................................1716 Disassembly and assembly of axle housing assembly ........................................................................................................................................1719 Disassembly and assembly of differential assembly ........................................................................................................................................1731 Undercarriage and frame ......................................................................................................................................................................1753 Removal and installation of center hinge pin .............................................................................................................................................1753 Removal and installation of counterweight assembly .......................................................................................................................................1762 Hydraulic system .............................................................................................................................................................................1766 Removal and installation of hydraulic tank assembly ......................................................................................................................................1766 Removal and installation of control valve assembly .......................................................................................................................................1770 Disassembly and assembly of control valve assembly .......................................................................................................................................1774 Removal and installation of hydraulic pump assembly ......................................................................................................................................1777 Removal and installation of HST motor1 assembly ..........................................................................................................................................1782 Removal and installation of HST motor2 assembly ..........................................................................................................................................1784 Disassembly and assembly of hydraulic cylinder assembly ..................................................................................................................................1786 Work equipment ...............................................................................................................................................................................1793 Removal and installation of work equipment assembly ......................................................................................................................................1793 Cab and its attachments ......................................................................................................................................................................1799 Removal and installation of operator's cab and floor frame assembly ......................................................................................................................1799 Removal and installation of operator's cab glass (adhered glass) .........................................................................................................................1804 Removal and installation of operator's seat assembly .....................................................................................................................................1812 Removal and installation of seat belt ....................................................................................................................................................1814 Removal and installation of air conditioner unit assembly ................................................................................................................................1815 Removal and installation of air conditioner compressor ...................................................................................................................................1820 Removal and installation of air conditioner condenser ....................................................................................................................................1822 Electrical system ............................................................................................................................................................................1824 Removal and installation of machine monitor assembly .....................................................................................................................................1824 Removal and installation of engine controller assembly ...................................................................................................................................1826 Removal and installation of HST controller assembly ......................................................................................................................................1828 Removal and installation of air conditioner controller assembly ..........................................................................................................................1830 Removal and installation of monitor controller assembly ..................................................................................................................................1831 Removal and installation of mass air flow and temperature sensor .........................................................................................................................1833 Removal and installation of KOMTRAX terminal assembly ....................................................................................................................................1834 60 Maintenance standard ..........................................................................................................................................................................1835 Table of contents ............................................................................................................................................................................1836 Engine and cooling system ....................................................................................................................................................................1837 Engine related parts .....................................................................................................................................................................1837 Cooling fan motor ........................................................................................................................................................................1838 Power train ..................................................................................................................................................................................1840 Damper ...................................................................................................................................................................................1840 Transfer .................................................................................................................................................................................1841 Drive shaft ..............................................................................................................................................................................1848 Axle .....................................................................................................................................................................................1849 Differential .............................................................................................................................................................................1851 Limited slip differential ................................................................................................................................................................1855 Final drive ..............................................................................................................................................................................1857 Steering system ..............................................................................................................................................................................1859 Steering column ..........................................................................................................................................................................1859 Priority valve ...........................................................................................................................................................................1860 Emergency steering valve .................................................................................................................................................................1861 Steering cylinder ........................................................................................................................................................................1862 Brake system .................................................................................................................................................................................1864 Brake accumulator charge valve ...........................................................................................................................................................1864 Slack adjuster ...........................................................................................................................................................................1865 Brake ....................................................................................................................................................................................1866 Parking brake ............................................................................................................................................................................1868 Parking brake solenoid valve .............................................................................................................................................................1869 Undercarriage and frame ......................................................................................................................................................................1870 Axle mount ...............................................................................................................................................................................1870 Center hinge pin .........................................................................................................................................................................1872 Hydraulic system .............................................................................................................................................................................1875 Hydraulic tank ...........................................................................................................................................................................1875 Double type gear pump ....................................................................................................................................................................1876 Steering and work equipment pump .........................................................................................................................................................1877 Control valve ............................................................................................................................................................................1881 Self-pressure reducing valve .............................................................................................................................................................1894 Work equipment PPC valve .................................................................................................................................................................1896 Work equipment lock solenoid valve .......................................................................................................................................................1898 Work equipment ...............................................................................................................................................................................1899 Work equipment linkage ...................................................................................................................................................................1899 Bucket ...................................................................................................................................................................................1903 Work equipment cylinder ..................................................................................................................................................................1905 Cab and its attachments ......................................................................................................................................................................1906 Cab mount ................................................................................................................................................................................1906 Electrical system ............................................................................................................................................................................1907 Bucket positioner ........................................................................................................................................................................1907 Fork positioner ..........................................................................................................................................................................1908 Remote boom positioner ...................................................................................................................................................................1909 80 Appendix ......................................................................................................................................................................................1911 Table of contents ............................................................................................................................................................................1912 Air conditioner components ...................................................................................................................................................................1913 Precautions for refrigerant ..............................................................................................................................................................1913 Air conditioner component ................................................................................................................................................................1914 Configuration and function of refrigeration cycle ........................................................................................................................................1916 Outline of refrigeration cycle ...........................................................................................................................................................1917 Air conditioner unit .....................................................................................................................................................................1919 Dual pressure switch .....................................................................................................................................................................1924 Air conditioner controller ...............................................................................................................................................................1925 Compressor ...............................................................................................................................................................................1926 Condenser ................................................................................................................................................................................1927 Receiver drier ...........................................................................................................................................................................1928 Sunlight sensor ..........................................................................................................................................................................1930 Outer temperature sensor (outside air temperature sensor) ................................................................................................................................1931 Procedure for testing and troubleshooting ................................................................................................................................................1932 Circuit diagram and arrangement of connector pins ........................................................................................................................................1934 System diagram ...........................................................................................................................................................................1937 Parts and connectors layout ..............................................................................................................................................................1940 Testing with self-diagnosis function .....................................................................................................................................................1945 How to open the electrical system abnormality record screen in service mode of the machine monitor .......................................................................................1946 Testing temperature control system .......................................................................................................................................................1948 Testing vent (mode) changeover ...........................................................................................................................................................1950 Testing FRESH/RECIRC air changeover ......................................................................................................................................................1952 Testing evaporator temperature sensor ....................................................................................................................................................1954 Testing relays ...........................................................................................................................................................................1956 Troubleshooting chart 1 ..................................................................................................................................................................1958 Troubleshooting chart 2 ..................................................................................................................................................................1959 Information in troubleshooting table .....................................................................................................................................................1961 Failure code list related to air conditioner .............................................................................................................................................1962 Failure code [879AKA] A/C Inner Sensor Open Circuit ......................................................................................................................................1963 Failure code [879AKB] A/C Inner Sensor Short Circuit .....................................................................................................................................1965 Failure code [879BKA] A/C Outer Sensor Open Circuit ......................................................................................................................................1967 Failure code [879BKB] A/C Outer Sensor Short Circuit .....................................................................................................................................1969 Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................................................................................................1971 Failure code [879CKB] Ventilating Sensor Short Circuit ...................................................................................................................................1973 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..............................................................................................................................1975 Failure code [879EMC] Ventilation Damper Abnormality .....................................................................................................................................1977 Failure code [879FMC] Air Mix Damper Abnormality .........................................................................................................................................1980 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) .....................................................................................1983 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................................................................................................1986 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...................................................................................................1989 A-4 Troubleshooting for FRESH/RECIRC air changeover ......................................................................................................................................1992 Troubleshooting with gauge pressure ......................................................................................................................................................1994 Connection of service tool ...............................................................................................................................................................1997 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ..................................................................................................1999 Handling of compressor oil ...............................................................................................................................................................2001 90 Diagrams and drawings .........................................................................................................................................................................2003 Table of contents ............................................................................................................................................................................2004 Hydraulic circuit diagram ....................................................................................................................................................................2005 Symbols in hydraulic circuit diagram .....................................................................................................................................................2005 Hydraulic circuit diagram ................................................................................................................................................................2009 Electric circuit diagram .....................................................................................................................................................................2010 Symbols in electric circuit diagram ......................................................................................................................................................2010 Electrical circuit diagram of machine body ...............................................................................................................................................2014 Electrical circuit diagram of floor ......................................................................................................................................................2018 INDEX.............................................................................................................................................................................................2027
KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL SEN06202-00 – PDF DOWNLOAD:
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