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KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL VENBM27500 – PDF DOWNLOAD
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KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL VENBM27500 – PDF DOWNLOAD
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KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL VENBM27500 – PDF DOWNLOAD
Language : English
Pages : 2069
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL VENBM27500 – PDF DOWNLOAD
VENBM29500 WA320-7................................................................................................................................................................................ 1 00 Index and foreword ............................................................................................................................................................................ 3 Index ........................................................................................................................................................................................ 4 Foreword, safety and general information ..................................................................................................................................................... 19 Important safety notice .................................................................................................................................................................. 19 How to read the shop manual .............................................................................................................................................................. 26 Explanation of terms for maintenance standard ............................................................................................................................................ 28 Handling equipment of fuel system devices ................................................................................................................................................ 30 Handling of intake system parts .......................................................................................................................................................... 31 Handling of hydraulic equipment .......................................................................................................................................................... 32 Method of disconnecting and connecting of push-pull type coupler ......................................................................................................................... 34 Handling of electrical equipment ......................................................................................................................................................... 37 How to read electric wire code ........................................................................................................................................................... 45 Precautions when performing operation .................................................................................................................................................... 48 Practical use of KOMTRAX ................................................................................................................................................................. 53 Standard tightening torque table ......................................................................................................................................................... 54 List of abbreviation ..................................................................................................................................................................... 60 Conversion table ......................................................................................................................................................................... 65 01 Specification ................................................................................................................................................................................. 71 Table of contents ............................................................................................................................................................................ 72 Specifications ............................................................................................................................................................................... 73 Specification drawing .................................................................................................................................................................... 73 Specifications ........................................................................................................................................................................... 77 Weight table ............................................................................................................................................................................. 87 Table of fuel, coolant, and lubricants ................................................................................................................................................... 91 10 Structure and function ........................................................................................................................................................................ 93 Table of contents ............................................................................................................................................................................ 94 Engine and cooling system .................................................................................................................................................................... 96 Engine related parts ..................................................................................................................................................................... 96 KVGT ..................................................................................................................................................................................... 98 EGR system piping drawing ................................................................................................................................................................ 105 EGR system circuit diagram ............................................................................................................................................................... 107 EGR valve ................................................................................................................................................................................ 109 EGR cooler ............................................................................................................................................................................... 111 KCCV layout drawing ...................................................................................................................................................................... 112 KCCV ventilator .......................................................................................................................................................................... 114 KDPF ..................................................................................................................................................................................... 116 Cooling system ........................................................................................................................................................................... 120 Cooling fan motor ........................................................................................................................................................................ 122 Power train .................................................................................................................................................................................. 132 Power train system ....................................................................................................................................................................... 132 Layout of power train parts .............................................................................................................................................................. 134 Damper ................................................................................................................................................................................... 135 HST pump ................................................................................................................................................................................. 136 HST motor1 ............................................................................................................................................................................... 149 HST motor2 ............................................................................................................................................................................... 151 Transfer ................................................................................................................................................................................. 156 Clutch solenoid valve .................................................................................................................................................................... 163 Drive shaft .............................................................................................................................................................................. 165 Axle ..................................................................................................................................................................................... 166 Differential ............................................................................................................................................................................. 168 Torque proportional differential ......................................................................................................................................................... 172 Limited slip differential ................................................................................................................................................................ 174 Final drive .............................................................................................................................................................................. 179 Steering system .............................................................................................................................................................................. 181 Layout of steering devices ............................................................................................................................................................... 181 Steering column .......................................................................................................................................................................... 182 Priority valve ........................................................................................................................................................................... 183 Cushion valve ............................................................................................................................................................................ 187 Emergency steering valve ................................................................................................................................................................. 188 Orbitrol valve ........................................................................................................................................................................... 191 Brake system ................................................................................................................................................................................. 197 Layout of brake parts .................................................................................................................................................................... 197 Brake accumulator charge valve ........................................................................................................................................................... 199 Brake valve .............................................................................................................................................................................. 204 Brake accumulator ........................................................................................................................................................................ 208 Slack adjuster ........................................................................................................................................................................... 209 Brake .................................................................................................................................................................................... 211 Parking brake control .................................................................................................................................................................... 214 Parking brake ............................................................................................................................................................................ 215 Parking brake solenoid valve ............................................................................................................................................................. 216 Undercarriage and frame ...................................................................................................................................................................... 218 Axle mount ............................................................................................................................................................................... 218 Center hinge pin ......................................................................................................................................................................... 220 Tire ..................................................................................................................................................................................... 221 Hydraulic system ............................................................................................................................................................................. 223 Hydraulic component layout ............................................................................................................................................................... 223 Work equipment control ................................................................................................................................................................... 225 Hydraulic tank ........................................................................................................................................................................... 226 Double type gear pump .................................................................................................................................................................... 229 Steering and work equipment pump ......................................................................................................................................................... 230 Control valve ............................................................................................................................................................................ 242 CLSS ..................................................................................................................................................................................... 252 Hydraulic circuit diagram and names of valves ............................................................................................................................................ 256 Self-pressure reducing valve ............................................................................................................................................................. 269 Work equipment PPC valve ................................................................................................................................................................. 274 Work equipment lock solenoid valve ....................................................................................................................................................... 282 PPC circuit accumulator .................................................................................................................................................................. 283 ECSS accumulator ......................................................................................................................................................................... 284 Work equipment ............................................................................................................................................................................... 285 Work equipment linkage ................................................................................................................................................................... 285 Bucket ................................................................................................................................................................................... 286 Cab and its attachments ...................................................................................................................................................................... 287 ROPS cab ................................................................................................................................................................................. 287 Cab mount ................................................................................................................................................................................ 289 Electrical system ............................................................................................................................................................................ 290 Engine control system .................................................................................................................................................................... 290 Preheating system ........................................................................................................................................................................ 293 Engine output limit function ............................................................................................................................................................. 295 Automatic warm-up function ............................................................................................................................................................... 296 Parking brake control system ............................................................................................................................................................. 297 System operating lamp function ........................................................................................................................................................... 301 Battery disconnect switch function ....................................................................................................................................................... 302 HST controller system .................................................................................................................................................................... 304 Machine monitor system ................................................................................................................................................................... 344 Rearview monitor system .................................................................................................................................................................. 365 KOMTRAX system ........................................................................................................................................................................... 368 System component parts ................................................................................................................................................................... 371 Sensor ................................................................................................................................................................................... 394 Central lubrication system (CLS).............................................................................................................................................................. 415 Auto-grease pump.......................................................................................................................................................................... 415 Changing the lubrication interval times................................................................................................................................................... 416 Check central lubrication system, fill up grease.......................................................................................................................................... 420 20 Standard value tables ......................................................................................................................................................................... 423 Table of contents ............................................................................................................................................................................ 424 Standard service value table ................................................................................................................................................................. 425 Standard value table for engine .......................................................................................................................................................... 425 Standard value table for machine ......................................................................................................................................................... 427 Standard value table for electrical system ............................................................................................................................................... 439 30 Testing and adjusting ......................................................................................................................................................................... 449 Table of contents ............................................................................................................................................................................ 450 Related information on testing and adjusting ................................................................................................................................................. 452 Tools for testing and adjusting .......................................................................................................................................................... 452 Sketch of tools for testing and adjusting ................................................................................................................................................ 458 Engine and cooling system .................................................................................................................................................................... 459 Testing engine speed ..................................................................................................................................................................... 459 Testing boost pressure ................................................................................................................................................................... 460 Testing exhaust gas temperature .......................................................................................................................................................... 462 Testing exhaust gas color ................................................................................................................................................................ 463 Testing and adjusting valve clearance .................................................................................................................................................... 465 Testing compression pressure ............................................................................................................................................................. 468 Testing blowby pressure .................................................................................................................................................................. 472 Testing engine oil pressure .............................................................................................................................................................. 473 Testing EGR valve and KVGT driving oil pressure .......................................................................................................................................... 474 Testing fuel pressure .................................................................................................................................................................... 475 Testing fuel discharge, return and leakage ............................................................................................................................................... 480 Bleeding air from fuel system ............................................................................................................................................................ 485 Testing fuel circuit for leakage ......................................................................................................................................................... 487 Handling cylinder cutout mode operation .................................................................................................................................................. 488 Handling no-injection cranking operation ................................................................................................................................................. 489 Testing of KDPF and muffler stack for looseness and damage ............................................................................................................................... 490 Testing of installed condition of cylinder heads and manifolds ........................................................................................................................... 491 Testing engine piping for damage and looseness ........................................................................................................................................... 492 Testing and adjusting air conditioner compressor belt tension ............................................................................................................................ 493 Replacing alternator belt ................................................................................................................................................................ 494 Power train .................................................................................................................................................................................. 495 Testing oil leakage from axle final drive ................................................................................................................................................ 495 Testing drive shaft for looseness, backlash, and damage .................................................................................................................................. 496 Testing accelerator pedal ................................................................................................................................................................ 497 Testing and adjusting HST oil pressure ................................................................................................................................................... 498 Testing transfer clutch control pressure ................................................................................................................................................. 501 Steering system .............................................................................................................................................................................. 502 Testing directional lever ................................................................................................................................................................ 502 Testing steering wheel ................................................................................................................................................................... 503 Testing work equipment control lever ..................................................................................................................................................... 505 Testing and adjusting steering circuit oil pressure ...................................................................................................................................... 507 Bleeding air from steering cylinder circuit .............................................................................................................................................. 509 Brake system ................................................................................................................................................................................. 510 Testing brake pedal ...................................................................................................................................................................... 510 Testing braking performance .............................................................................................................................................................. 511 Testing and adjusting of accumulator charge pressure ..................................................................................................................................... 512 Testing wheel brake oil pressure ......................................................................................................................................................... 514 Testing lowering of wheel brake pressure ................................................................................................................................................. 515 Testing wear of wheel brake disc ......................................................................................................................................................... 517 Bleeding air from wheel brake circuit .................................................................................................................................................... 518 Releasing remaining pressure in brake accumulator circuit ................................................................................................................................ 519 Testing parking brake performance ........................................................................................................................................................ 520 Testing wear of parking brake disc ....................................................................................................................................................... 521 Testing parking brake release pressure ................................................................................................................................................... 522 Method of releasing parking brake manually ............................................................................................................................................... 523 Hydraulic system ............................................................................................................................................................................. 524 Testing cooling fan speed ................................................................................................................................................................ 524 Testing cooling fan pump circuit oil pressure ............................................................................................................................................ 525 Bleeding air from hydraulic fan circuit .................................................................................................................................................. 527 Testing and adjusting work equipment PPC oil pressure .................................................................................................................................... 528 Testing and adjusting work equipment oil pressure ........................................................................................................................................ 530 Bleeding air from work equipment circuit ................................................................................................................................................. 534 Releasing remaining pressure from work equipment circuit ................................................................................................................................. 535 Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas .................................................................................. 537 Work equipment ............................................................................................................................................................................... 541 Testing and adjusting bucket positioner and bucket proximity switch ...................................................................................................................... 541 Testing and adjusting boom position detection lever ...................................................................................................................................... 543 Electrical system ............................................................................................................................................................................ 544 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ................................................................................................... 544 Special functions of machine monitor ..................................................................................................................................................... 545 Adjusting rearview camera angle .......................................................................................................................................................... 624 Handling voltage circuit of engine controller ............................................................................................................................................ 625 Handling battery disconnect switch ....................................................................................................................................................... 626 Testing diodes ........................................................................................................................................................................... 627 Pm clinic .................................................................................................................................................................................... 628 Pm Clinic service ........................................................................................................................................................................ 628 Check sheet .............................................................................................................................................................................. 629 40 Troubleshooting ............................................................................................................................................................................... 635 Table of contents ............................................................................................................................................................................ 636 Related information on troubleshooting ....................................................................................................................................................... 645 Troubleshooting points ................................................................................................................................................................... 645 Sequence of events in troubleshooting .................................................................................................................................................... 647 Checks before troubleshooting ............................................................................................................................................................ 649 Inspection procedure before troubleshooting .............................................................................................................................................. 651 Preparation for troubleshooting of electrical system ..................................................................................................................................... 668 Classification and procedures for troubleshooting ........................................................................................................................................ 674 Symptom and troubleshooting numbers ...................................................................................................................................................... 677 Information in troubleshooting table ..................................................................................................................................................... 680 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit .................................................................................................. 682 Connector list and layout ................................................................................................................................................................ 685 Connector contact identification ......................................................................................................................................................... 699 T-branch box and T-branch adapter table .................................................................................................................................................. 737 Fuse location table ...................................................................................................................................................................... 742 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ............................................................................................................................ 745 Precautions when performing troubleshooting of machine monitor ........................................................................................................................... 748 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit .................................................................................................. 750 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .......................................................................................................... 755 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) .............................................................................................. 756 Failure codes table ...................................................................................................................................................................... 757 Troubleshooting by failure code (Display of code) ............................................................................................................................................ 769 Failure code [2F00MA] Failure of Parking Brake Circuit ................................................................................................................................... 769 Failure code [2F00MB] Malfunction of Parking Brake ....................................................................................................................................... 772 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................................................................................................... 774 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ................................................................................................................................ 776 Failure code [6091NX] HST Oil Filter Clogging ............................................................................................................................................ 778 Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ......................................................................................................................... 780 Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. .......................................................................................................................... 782 Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ............................................................................................................................. 784 Failure code [879AKA] A/C Inner Sensor Open Circuit ...................................................................................................................................... 786 Failure code [879AKB] A/C Inner Sensor Short Circuit ..................................................................................................................................... 787 Failure code [879BKA] A/C Outer Sensor Open Circuit ...................................................................................................................................... 788 Failure code [879BKB] A/C Outer Sensor Short Circuit ..................................................................................................................................... 789 Failure code [879CKA] Ventilating Sensor Open Circuit .................................................................................................................................... 790 Failure code [879CKB] Ventilating Sensor Short Circuit ................................................................................................................................... 791 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................................................................................................. 792 Failure code [879EMC] Ventilation Damper Abnormality ..................................................................................................................................... 793 Failure code [879FMC] Air Mix Damper Abnormality ......................................................................................................................................... 794 Failure code [989L00] Engine Controller Lock Caution 1 ................................................................................................................................... 795 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................................................................................... 796 Failure code [989N00] Engine Controller Lock Caution 3 ................................................................................................................................... 797 Failure code [A1U0N3] HC Desorb Request 1 ................................................................................................................................................ 798 Failure code [A1U0N4] HC Desorb Request 2 ................................................................................................................................................ 800 Failure code [AA10NX] Air Cleaner Clogging ............................................................................................................................................... 802 Failure code [B@BAZG] Eng Oil Press Low .................................................................................................................................................. 804 Failure code [B@BAZK] Engine Oil Level Low ............................................................................................................................................... 805 Failure code [B@BCNS] Eng Water Overheat ................................................................................................................................................. 807 Failure code [B@BCZK] Eng Water Level Low ................................................................................................................................................ 808 Failure code [B@CRNS] HST Oil Temp. Overheat ............................................................................................................................................. 810 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................................................................................................... 811 Failure code [CA122] Chg Air Press Sensor High Error ..................................................................................................................................... 812 Failure code [CA123] Chg Air Press Sensor Low Error ...................................................................................................................................... 814 Failure code [CA131] Throttle Sensor High Error .......................................................................................................................................... 816 Failure code [CA132] Throttle Sensor Low Error ........................................................................................................................................... 818 Failure code [CA144] Coolant Temp Sens High Error ........................................................................................................................................ 820 Failure code [CA145] Coolant Temp Sens Low Error ......................................................................................................................................... 822 Failure code [CA153] Chg Air Temp Sensor High Error ...................................................................................................................................... 824 Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................................................................................................... 826 Failure code [CA187] Sensor 2 Supply Volt Low Error ...................................................................................................................................... 828 Failure code [CA221] Ambient Press Sensor High Error ..................................................................................................................................... 830 Failure code [CA222] Ambient Press Sensor Low Error ...................................................................................................................................... 832 Failure code [CA227] Sensor 2 Supply Volt High Error ..................................................................................................................................... 834 Failure code [CA234] Eng Overspeed ....................................................................................................................................................... 835 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................................................................................................... 836 Failure code [CA239] Ne Speed Sens Supply Volt High Error ................................................................................................................................ 837 Failure code [CA271] IMV/PCV1 Short Error ................................................................................................................................................ 838 Failure code [CA272] IMV/PCV1 Open Error ................................................................................................................................................. 840 Failure code [CA295] Ambient Press Sens In Range Error ................................................................................................................................... 842 Failure code [CA322] Inj #1(L#1) Open/Short Error ........................................................................................................................................ 843 Failure code [CA323] Inj #5(L#5) Open/Short Error ........................................................................................................................................ 845 Failure code [CA324] Inj #3(L#3) Open/Short Error ........................................................................................................................................ 847 Failure code [CA325] Inj #6(L#6) Open/Short Error ........................................................................................................................................ 849 Failure code [CA331] Inj #2(L#2) Open/Short Error ........................................................................................................................................ 851 Failure code [CA332] Inj #4(L#4) Open/Short Error ........................................................................................................................................ 853 Failure code [CA343] ECM Critical Internal Failure ....................................................................................................................................... 855 Failure code [CA351] Injectors Drive Circuit Error ....................................................................................................................................... 856 Failure code [CA352] Sensor 1 Supply Volt Low Error ...................................................................................................................................... 857 Failure code [CA356] Mass Air Flow Sensor High Error ..................................................................................................................................... 859 Failure code [CA357] Mass Air Flow Sensor Low Error ...................................................................................................................................... 861 Failure code [CA386] Sensor 1 Supply Volt High Error ..................................................................................................................................... 863 Failure code [CA428] Water in Fuel Sensor High Error ..................................................................................................................................... 864 Failure code [CA429] Water in Fuel Sensor Low Error ...................................................................................................................................... 866 Failure code [CA431] Idle Validation Sw Error ............................................................................................................................................ 868 Failure code [CA432] Idle Validation Process Error ....................................................................................................................................... 871 Failure code [CA435] Eng Oil Press Sw Error .............................................................................................................................................. 874 Failure code [CA441] Battery Voltage Low Error ........................................................................................................................................... 875 Failure code [CA442] Battery Voltage High Error .......................................................................................................................................... 877 Failure code [CA449] Rail Press Very High Error .......................................................................................................................................... 878 Failure code [CA451] Rail Press Sensor High Error ........................................................................................................................................ 879 Failure code [CA452] Rail Press Sensor Low Error ......................................................................................................................................... 881 Failure code [CA488] Chg Air Temp High Torque Derate ..................................................................................................................................... 883 Failure code [CA515] Rail Press Sens Sup Volt High Error ................................................................................................................................. 884 Failure code [CA516] Rail Press Sens Sup Volt Low Error .................................................................................................................................. 886 Failure code [CA553] Rail Press High Error ............................................................................................................................................... 888 Failure code [CA555] Crankcase Press High Error 1 ........................................................................................................................................ 889 Failure code [CA556] Crankcase Press High Error 2 ........................................................................................................................................ 890 Failure code [CA559] Rail Press Low Error ................................................................................................................................................ 891 Failure code [CA595] Turbo Speed High Error 2 ............................................................................................................................................ 893 Failure code [CA687] Turbo Speed Low Error ............................................................................................................................................... 894 Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................................................................................... 896 Failure code [CA691] Intake Air Temp Sens High Error ..................................................................................................................................... 898 Failure code [CA692] Intake Air Temp Sens Low Error ...................................................................................................................................... 900 Failure code [CA697] ECM Internal Temp Sensor High Error ................................................................................................................................. 902 Failure code [CA698] ECM Int Temp Sensor Low Error ....................................................................................................................................... 903 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..................................................................................................................................... 904 Failure code [CA778] Eng Bkup Speed Sensor Error ......................................................................................................................................... 906 Failure code [CA1117] Persistent Data Lost Error ......................................................................................................................................... 911 Failure code [CA1664] KDOC Malfunction ................................................................................................................................................... 912 Failure code [CA1691] Regeneration Ineffective ........................................................................................................................................... 915 Failure code [CA1695] Sensor 5 Supply Volt High Error .................................................................................................................................... 918 Failure code [CA1696] Sensor 5 Supply Volt Low Error ..................................................................................................................................... 919 Failure code [CA1843] Crankcase Press Sens High Error .................................................................................................................................... 921 Failure code [CA1844] Crankcase Press Sens Low Error ..................................................................................................................................... 923 Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................................................................................................... 925 Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................................................................................................... 927 Failure code [CA1883] KDPF Delta P Sens In Range Error ................................................................................................................................... 929 Failure code [CA1921] KDPF Soot Load High Error 1 ........................................................................................................................................ 933 Failure code [CA1922] KDPF Soot Load High Error 2 ........................................................................................................................................ 936 Failure code [CA1942] Crankcase Press Sens In Range Error ................................................................................................................................ 941 Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................................................................................................... 942 Failure code [CA2185] Throt Sensor Sup Volt High Error ................................................................................................................................... 945 Failure code [CA2186] Throt Sensor Sup Volt Low Error .................................................................................................................................... 947 Failure code [CA2249] Rail Press Very Low Error .......................................................................................................................................... 949 Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................................................................................................... 950 Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................................................................................................... 952 Failure code [CA2288] Turbo Speed High Error 1 ........................................................................................................................................... 955 Failure code [CA2311] IMV Solenoid Error ................................................................................................................................................. 956 Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................................................................................................... 957 Failure code [CA2353] EGR Valve Solenoid Short Error ..................................................................................................................................... 959 Failure code [CA2357] EGR Valve Servo Error .............................................................................................................................................. 961 Failure code [CA2373] Exhaust Manifold Press Sens High error ............................................................................................................................. 962 Failure code [CA2374] Exhaust Manifold Press Sens Low error .............................................................................................................................. 964 Failure code [CA2375] EGR Orifice Temp Sens High Error ................................................................................................................................... 966 Failure code [CA2376] EGR Orifice Temp Sens Low Error .................................................................................................................................... 968 Failure code [CA2381] KVGT Pos Sens High Error ........................................................................................................................................... 970 Failure code [CA2382] KVGT Pos Sens Low Error ............................................................................................................................................ 972 Failure code [CA2383] KVGT Solenoid Open Error ........................................................................................................................................... 975 Failure code [CA2386] KVGT Solenoid Short Error .......................................................................................................................................... 977 Failure code [CA2387] KVGT Servo Error ................................................................................................................................................... 979 Failure code [CA2554] Exh Manifold Press Sens In Range Error ............................................................................................................................. 980 Failure code [CA2555] Grid Htr Relay Volt Low Error ...................................................................................................................................... 981 Failure code [CA2556] Grid Htr Relay Volt High Error ..................................................................................................................................... 983 Failure code [CA2637] KDOC Face Plugging ................................................................................................................................................. 985 Failure code [CA2639] Manual Stationary Regeneration Request ............................................................................................................................. 987 Failure code [CA2961] EGR Orifice Temp High Error 1 ...................................................................................................................................... 990 Failure code [CA2973] Chg Air Press Sensor In Range Error ................................................................................................................................ 991 Failure code [CA3133] KDPF Outlet Press Sens High Error .................................................................................................................................. 992 Failure code [CA3134] KDPF Outlet Press Sens Low Error ................................................................................................................................... 994 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .............................................................................................................................. 996 Failure code [CA3251] KDOC Inlet Temp High Error .........................................................................................................................................1000 Failure code [CA3253] KDOC Temp Error - Non Regeneration .................................................................................................................................1003 Failure code [CA3254] KDOC Outlet Temp High Error 1 ......................................................................................................................................1006 Failure code [CA3255] KDPF Temp Error - Non Regeneration .................................................................................................................................1009 Failure code [CA3256] KDPF Outlet Temp High Error 1 ......................................................................................................................................1012 Failure code [CA3311] KDOC Outlet Temp High Error 2 ......................................................................................................................................1015 Failure code [CA3312] KDPF Outlet Temp High Error 2 ......................................................................................................................................1018 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...................................................................................................................................1021 Failure code [CA3314] KDOC Inlet Temp Sens High Error ....................................................................................................................................1024 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ................................................................................................................................1027 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....................................................................................................................................1031 Failure code [CA3317] KDOC Outlet Temp Sens High Error ...................................................................................................................................1034 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...............................................................................................................................1037 Failure code [CA3319] KDPF Outlet Temp Sens High Error ...................................................................................................................................1041 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....................................................................................................................................1044 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...............................................................................................................................1047 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...........................................................................................................................1051 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ............................................................................................................................1053 Failure code [CA3741] Rail Press Valve Trip Error ........................................................................................................................................1055 Failure code [D110L4] Disconnection of Battery Relay Signal ..............................................................................................................................1056 Failure code [D160KA] Disconnection of Backup Lamp Relay Output ..........................................................................................................................1058 Failure code [D160KY] Hot Short of Backup Lamp Relay Output ..............................................................................................................................1060 Failure code [D191KA] Disconnection of Neutral Output Relay ..............................................................................................................................1062 Failure code [D191KB] Ground Fault of Neutral Output Relay ...............................................................................................................................1064 Failure code [D191KY] Hot Short of Neutral Output Relay ..................................................................................................................................1066 Failure code [D192KA] Disconnection of ECSS Solenoid .....................................................................................................................................1068 Failure code [D192KB] Ground Fault of ECSS Solenoid ......................................................................................................................................1070 Failure code [D192KY] Hot Short of ECSS Solenoid .........................................................................................................................................1071 Failure code [D19JKZ] Personal Code Relay Abnormality ....................................................................................................................................1072 Failure code [D1B0KA] Disconnection of HST Safety Relay ..................................................................................................................................1074 Failure code [D1B0KB] Ground Fault of HST Safety Relay ...................................................................................................................................1076 Failure code [D1B0KY] Hot Short of HST Safety Relay ......................................................................................................................................1078 Failure code [D1B0MC] Malfunction of HST Safety Relay ....................................................................................................................................1080 Failure code [D1E6KA] Disconnection of Parking Brake Relay ...............................................................................................................................1081 Failure code [D1E6KB] Ground Fault of Parking Brake Relay ................................................................................................................................1083 Failure code [D1E6KY] Hot Short of Parking Brake Relay ...................................................................................................................................1085 Failure code [D5ZHKA] Failure of Key SW C Signal .........................................................................................................................................1087 Failure code [D5ZHKB] Key SW C Signal Short Circuit ......................................................................................................................................1089 Failure code [D5ZHL6] Disconnection of Key SW C ..........................................................................................................................................1091 Failure code [D811MC] KOMTRAX Error ......................................................................................................................................................1092 Failure code [D862KA] GPS Antenna Open Circuit ...........................................................................................................................................1093 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ..............................................................................................................................1094 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .............................................................................................................................1096 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ............................................................................................................................................1098 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..............................................................................................................................................1099 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...........................................................................................................................1101 Failure code [DAF0MB] Monitor ROM Abnormality ............................................................................................................................................1102 Failure code [DAF0MC] Monitor Error ......................................................................................................................................................1103 Failure code [DAF3KK] Controller Power Source Low (MON) ..................................................................................................................................1104 Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................................................................................................1106 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .............................................................................................................................1107 Failure code [DAFGMC] GPS Module Error ...................................................................................................................................................1108 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ..................................................................................................................................1109 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) .................................................................................................................................1111 Failure code [DAFQKR] CAN2 Discon (Monitor) ..............................................................................................................................................1113 Failure code [DAJ0KK] Controller Power Source Low (HST) ..................................................................................................................................1114 Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ...........................................................................................................................1117 Failure code [DAJ0MC] HST Con Error ......................................................................................................................................................1118 Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ..................................................................................................................................1119 Failure code [DAJ2KK] Solenoid Power Source Low (HST) ....................................................................................................................................1121 Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ............................................................................................................................1124 Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay .................................................................................................................................1126 Failure code [DAJ5KX] Failure of 5V Power Source 0 .......................................................................................................................................1128 Failure code [DAJ6KX] Failure of 5V Power Source 1 .......................................................................................................................................1130 Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) .............................................................................................................................1132 Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ..................................................................................................................................1133 Failure code [DAJLKB] Operating Lamp Short Circuit (HST) .................................................................................................................................1135 Failure code [DAJQKR] CAN2 Discon ( HST Con) .............................................................................................................................................1137 Failure code [DAJRKR] CAN1 Discon ( HST Con) .............................................................................................................................................1138 Failure code [DAJRMA] Inconsistency of Option Selection (HST) ............................................................................................................................1139 Failure code [DAZ9KQ] A/C Model Selection Abnormality ....................................................................................................................................1140 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...........................................................................................................................................1141 Failure code [DB2QKR] CAN2 Discon (Engine Con) ...........................................................................................................................................1142 Failure code [DB2RKR] CAN1 Discon (Engine Con) ...........................................................................................................................................1147 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...........................................................................................................................1151 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch .........................................................................................................................1153 Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ................................................................................................................................1155 Failure code [DDB6L4] Parking Brake Signal Malfunction ...................................................................................................................................1157 Failure code [DDD7KA] Failure of Variable Speed Control ..................................................................................................................................1160 Failure code [DDD7KY] Hot Short of Variable Speed Control ................................................................................................................................1162 Failure code [DDK3KA] FNR SW Input Signal Disconnection ..................................................................................................................................1164 Failure code [DDK3KB] FNR SW Input Signal Short Circuit ..................................................................................................................................1166 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...............................................................................................................................1168 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...............................................................................................................................1171 Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ............................................................................................................................1173 Failure code [DF10KA] Disconnection of Speed Range Input .................................................................................................................................1175 Failure code [DF10KB] Ground Fault of Speed Range Input ..................................................................................................................................1178 Failure code [DGH1KX] Out of Range of HST Oil Temp. Sensor ...............................................................................................................................1181 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor .............................................................................................................................1183 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ..................................................................................................................................1185 Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ..............................................................................................................................1187 Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ...........................................................................................................................1189 Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) .........................................................................................................................1191 Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ...........................................................................................................................1193 Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) .........................................................................................................................1195 Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) .............................................................................................................................1197 Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ...........................................................................................................................1199 Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ...........................................................................................................................1201 Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. .........................................................................................................................1203 Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ............................................................................................................................1205 Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ..........................................................................................................................1207 Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ............................................................................................................................1209 Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ..........................................................................................................................1211 Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ...........................................................................................................................1213 Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit .........................................................................................................................1215 Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ...........................................................................................................................1217 Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit .........................................................................................................................1219 Failure code [DHT8ZG] Steering Oil Pressure Low ..........................................................................................................................................1221 Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ...........................................................................................................................1222 Failure code [DJF1KA] Disconnection of Fuel Level Sensor .................................................................................................................................1224 Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................................................................................................1226 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ............................................................................................................................1229 Failure code [DK55L5] Failure of FNR Lever Potentio ......................................................................................................................................1231 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...............................................................................................................................1232 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) .............................................................................................................................1235 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...........................................................................................................................1238 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ................................................................................................................................1241 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ..............................................................................................................................1244 Failure code [DK70KA] Failure of inching sensor Circuit ..................................................................................................................................1247 Failure code [DK70KY] Hot Short of inching sensor Circuit ................................................................................................................................1250 Failure code [DKA0KA] Failure of Boom Angle Sensor .......................................................................................................................................1252 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .............................................................................................................................1254 Failure code [DKA0L0] Boom Angle Sensor Dislocation ......................................................................................................................................1256 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor .........................................................................................................................1258 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...............................................................................................................................1260 Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ...........................................................................................................................1262 Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ...........................................................................................................................1264 Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ...............................................................................................................................1266 Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ..............................................................................................................................1269 Failure code [DPQ1KR] LIN Discon (Switch Panel) ..........................................................................................................................................1271 Failure code [DPQ2KR] LIN Discon (LED Unit) ..............................................................................................................................................1274 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) .....................................................................................................................................1277 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...........................................................................................................................................1280 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ............................................................................................................................1282 Failure code [DV00KB] Ground Fault of Buzzer Output ......................................................................................................................................1284 Failure code [DW26KA] Disconnection of Motor 2 Solenoid ..................................................................................................................................1286 Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ...................................................................................................................................1288 Failure code [DW26KY] Hot Short of Motor 2 Solenoid ......................................................................................................................................1290 Failure code [DW4BKA] Disconnection of Parking Brake Valve ...............................................................................................................................1292 Failure code [DW4BKB] Ground Fault of Parking Brake Valve ................................................................................................................................1294 Failure code [DW4BKY] Hot Short of Parking Brake Valve ...................................................................................................................................1296 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ............................................................................................................................1297 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .........................................................................................................................1299 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ............................................................................................................................1301 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid .............................................................................................................................1302 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ..............................................................................................................................1304 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid .................................................................................................................................1306 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ............................................................................................................................1307 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) .............................................................................................................................1309 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ................................................................................................................................1311 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..........................................................................................................................1313 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...........................................................................................................................1315 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ..............................................................................................................................1317 Failure code [DX19KA] Disconnection of Motor 1 Solenoid ..................................................................................................................................1318 Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ...................................................................................................................................1320 Failure code [DX19KY] Hot Short of Motor 1 Solenoid ......................................................................................................................................1322 Failure code [DX20KA] Disconnection of Clutch Control Solenoid ...........................................................................................................................1324 Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ............................................................................................................................1326 Failure code [DX20KY] Hot Short of Clutch Control Solenoid ...............................................................................................................................1328 Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. .................................................................................................................................1330 Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ..................................................................................................................................1332 Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. .....................................................................................................................................1334 Failure code [DXH7KA] Disconnection of Reverse Solenoid ..................................................................................................................................1336 Failure code [DXH7KB] Ground Fault of Reverse Solenoid ...................................................................................................................................1338 Failure code [DXH7KY] Hot Short of Reverse Solenoid ......................................................................................................................................1340 Failure code [DXH8KA] Disconnection of Forward Solenoid ..................................................................................................................................1342 Failure code [DXH8KB] Ground Fault of Forward Solenoid ...................................................................................................................................1344 Failure code [DXH8KY] Hot Short of Forward Solenoid ......................................................................................................................................1346 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ............................................................................................................................1348 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) .............................................................................................................................1350 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ................................................................................................................................1352 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ............................................................................................................................1353 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) .............................................................................................................................1355 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ................................................................................................................................1357 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...............................................................................................................................1358 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal .............................................................................................................................1361 Failure code [J141N1] Steering Pump Over Run .............................................................................................................................................1363 Failure code [LA00L3] Failure of Fan Reverse .............................................................................................................................................1364 Failure code [M100N1] HST Pump Over Run ..................................................................................................................................................1365 Failure code [M400N1] HST Motor 1 Over Run ...............................................................................................................................................1366 Troubleshooting of electrical system (E-mode) ................................................................................................................................................1367 E-1 Engine does not start ................................................................................................................................................................1367 E-2 Manual preheating system does not work ...............................................................................................................................................1374 E-3 Automatic preheating system does not work ............................................................................................................................................1377 E-4 While preheating is working, preheating monitor does not light up ....................................................................................................................1379 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .........................................................................................................1381 E-6 LCD unit on machine monitor displays nothing .........................................................................................................................................1384 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ................................................................................................1386 E-8 LCD on machine monitor does not display properly .....................................................................................................................................1388 E-9 Meter unit display on machine monitor is abnormal ....................................................................................................................................1390 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ....................................................................................................................1393 E-11 Caution LED on machine monitor is abnormal ..........................................................................................................................................1396 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ............................................................................................1398 E-13 Two switches operation of switch panel on machine monitor does not function .........................................................................................................1400 E-14 Switch panel buzzer of machine monitor is abnormal ..................................................................................................................................1403 E-15 Rearview monitor does not light up or backlight flickers ............................................................................................................................1405 E-16 Rearview monitor images are not displayed clearly ...................................................................................................................................1408 E-17 Rearview monitor brightness cannot be adjusted ......................................................................................................................................1411 E-18 Night lighting lamp of rearview monitor is abnormal .................................................................................................................................1414 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ................................................................................................1416 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ..................................................................................1417 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light .......................................................................................1421 E-22 Air cleaner clogging indicator lamp does not light ..................................................................................................................................1423 E-23 Radiator coolant level caution lamp does not light ..................................................................................................................................1425 E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light .......................................................................1427 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 ....1428 E-26 Fuel level gauge does not indicate correct level ....................................................................................................................................1430 E-27 Seat belt caution lamp indication is abnormal .......................................................................................................................................1432 E-28 Horn does not sound .................................................................................................................................................................1433 E-29 Horn does not stop sounding .........................................................................................................................................................1436 E-30 Alarm buzzer does not sound .........................................................................................................................................................1438 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding .........................................................................................................1440 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 ................1441 E-33 Setting does not change while operating traction control switch .....................................................................................................................1443 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 .......................................................1445 E-35 Remote positioner does not work or cannot be released ...............................................................................................................................1448 E-36 Bucket positioner does not work or cannot be released ...............................................................................................................................1450 E-37 Direction selector (FNR) switch mode is not selected or not released ................................................................................................................1453 E-38 PZ auto tilt-in does not work .......................................................................................................................................................1455 E-39 Tracktion level does not display MAX when max traction switch is turned ON ..........................................................................................................1458 E-40 ECSS function cannot be selected or cannot be released ..............................................................................................................................1460 E-41 None of headlamp, clearance lamp, and tail lamp lights ..............................................................................................................................1462 E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out ..........................................................................................................1464 E-43 Both High and Low beams of headlamp do not light up or go out .......................................................................................................................1468 E-44 Low beam of headlamp does not light up or go out ....................................................................................................................................1472 E-45 High beam of headlamp does not light up or go out ...................................................................................................................................1474 E-46 Front working lamp does not light up or go out ......................................................................................................................................1476 E-47 Rear working lamp does not light up or go out .......................................................................................................................................1480 E-48 All of turn signal lamps and hazard lamps do not flash or go out ....................................................................................................................1484 E-49 Turn signal lamps do not flash or go out ............................................................................................................................................1487 E-50 Hazard lamp does not flash or go out ................................................................................................................................................1490 E-51 Brake lamp does not light or stays lighted ..........................................................................................................................................1493 E-52 Backup lamp does not light up or does not go out ....................................................................................................................................1496 E-53 Backup buzzer does not sound or continues to sound ..................................................................................................................................1499 E-54 Front wiper does not operate ........................................................................................................................................................1501 E-55 Rear wiper does not operate .........................................................................................................................................................1504 E-56 Window washer does not operate ......................................................................................................................................................1506 E-57 KOMTRAX system does not operate normally ............................................................................................................................................1509 Troubleshooting of hydraulic and mechanical system (H-mode) ..................................................................................................................................1511 Information described in troubleshooting table (H-mode) ..................................................................................................................................1511 System chart of hydraulic and mechanical systems .........................................................................................................................................1512 Failure mode and cause table .............................................................................................................................................................1514 H-1 Machine does not travel forward or backward ..........................................................................................................................................1521 H-2 Machine does not travel forward (Machine travels backward normally) ..................................................................................................................1524 H-3 Machine does not travel backward (Machine travels forward normally) ..................................................................................................................1525 H-4 Machine does not travel forward or backward fast .....................................................................................................................................1526 H-5 Machine does not travel forward fast (Machine travel backward fast) ..................................................................................................................1530 H-6 Machine does not travel backward fast (Machine travel forward fast) ..................................................................................................................1531 H-7 Machine lacks power neither when traveling forward nor backward ......................................................................................................................1532 H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ....................................................................................1535 H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ...................................................................................1536 H-10 Engine stalls during travel or engine speed drops significantly .....................................................................................................................1537 H-11 Steering wheel is too heavy to turn .................................................................................................................................................1538 H-12 Steering wheel is heavy to turn .....................................................................................................................................................1540 H-13 Machine sways or large shocks are made while machine turns ..........................................................................................................................1541 H-14 Machine unintentionally turns when machine travels ..................................................................................................................................1542 H-15 Wheel brakes do not work or are weak ................................................................................................................................................1543 H-16 Wheel brakes are not released or drag ...............................................................................................................................................1544 H-17 Parking brake does not work or it is weak ...........................................................................................................................................1545 H-18 Parking brake is not released or drags. .............................................................................................................................................1546 H-19 Boom does not rise ..................................................................................................................................................................1547 H-20 Boom moves slow or boom lacks lifting force .........................................................................................................................................1549 H-21 Rising boom slows down at certain height ............................................................................................................................................1551 H-22 Lift cylinders do not serve to hold bucket (bucket rises off ground) ................................................................................................................1552 H-23 Hydraulic drift of boom is large ....................................................................................................................................................1553 H-24 Boom moves up and down during operation .............................................................................................................................................1554 H-25 Bucket does not tilt back ...........................................................................................................................................................1555 H-26 Bucket moves slow or lacks tilt force ...............................................................................................................................................1557 H-27 Bucket decelerates during tilt-back operation .......................................................................................................................................1559 H-28 Bucket cylinder does not hold bucket on ground ......................................................................................................................................1560 H-29 Hydraulic drift of bucket is large ..................................................................................................................................................1561 H-30 Bucket tilts back and forth during carrying load ....................................................................................................................................1562 H-31 Boom and bucket control levers do not move smoothly and are heavy to move ...........................................................................................................1563 H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ..............................................................................................1564 H-33 Large shocks are made when work equipment starts to move and stops ..................................................................................................................1565 H-34 When certain work equipment is relieved hydraulically, other work equipment moves ...................................................................................................1566 H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ..............................................................................................................1567 H-36 Fan speed is abnormal (too high or low, or fan does not rotate) .....................................................................................................................1568 H-37 Unusual noise is heard from around fan ..............................................................................................................................................1570 Troubleshooting of engine (S-mode) ...........................................................................................................................................................1571 Information described in troubleshooting table (S mode) ..................................................................................................................................1571 S-1 Engine does not crank when starting switch is turned to START position ...............................................................................................................1572 S-2 Engine cranks but no exhaust smoke comes out .........................................................................................................................................1573 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .......................................................................................1574 S-4 Engine startability is poor ..........................................................................................................................................................1575 S-5 Engine does not pick up smoothly .....................................................................................................................................................1577 S-6 Engine stops during operation ........................................................................................................................................................1579 S-7 Engine runs rough or is unstable .....................................................................................................................................................1581 S-8 Engine lacks power ...................................................................................................................................................................1582 S-9 KDPF gets clogged in a short time ....................................................................................................................................................1584 S-10 Engine oil consumption is excessive .................................................................................................................................................1586 S-11 Engine oil becomes contaminated early ...............................................................................................................................................1587 S-12 Fuel consumption is excessive .......................................................................................................................................................1588 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....................................................................................................................1589 S-14 Oil pressure drops ..................................................................................................................................................................1590 S-15 Fuel mixes into engine oil ..........................................................................................................................................................1591 S-16 Water mixes into engine oil (milky) .................................................................................................................................................1592 S-17 Coolant temperature rises too high (overheating) ....................................................................................................................................1593 S-18 Unusual noise is heard ..............................................................................................................................................................1594 S-19 Vibration is excessive ..............................................................................................................................................................1595 S-20 Air cannot be bled from fuel circuit ................................................................................................................................................1597 S-21 Active regeneration is executed frequently ..........................................................................................................................................1598 S-22 Active regeneration takes time ......................................................................................................................................................1599 S-23 White smoke is exhausted during active regeneration .................................................................................................................................1600 Troubleshooting of Central Lubrication System (CLS)...........................................................................................................................................1601 Troubleshooting FPS.......................................................................................................................................................................1601 Troubleshooting...........................................................................................................................................................................1602 Pump Faults...............................................................................................................................................................................1602 Pump faults...............................................................................................................................................................................1603 Replace pump element......................................................................................................................................................................1604 Check power supply........................................................................................................................................................................1604 Changing the control unit:................................................................................................................................................................1604 Troubleshooting – grease system faults....................................................................................................................................................1605 Venting of the system.....................................................................................................................................................................1606 General assembly advice...................................................................................................................................................................1607 50 Disassembly and assembly ......................................................................................................................................................................1609 Table of contents ............................................................................................................................................................................1610 Related information on disassembly and assembly ..............................................................................................................................................1612 How to read this manual ..................................................................................................................................................................1612 Coating materials list ...................................................................................................................................................................1614 Special tools list .......................................................................................................................................................................1618 Sketches of special tools ................................................................................................................................................................1623 Engine and cooling system ....................................................................................................................................................................1636 Removal and installation of supply pump assembly .........................................................................................................................................1636 Removal and installation of injector assembly ............................................................................................................................................1639 Removal and installation of cylinder head assembly .......................................................................................................................................1648 Removal and installation of engine hood assembly .........................................................................................................................................1661 Removal and installation of radiator core assembly .......................................................................................................................................1663 Removal and installation of aftercooler ..................................................................................................................................................1665 Removal and installation of hydraulic oil cooler .........................................................................................................................................1666 Removal and installation of engine assembly ..............................................................................................................................................1667 Removal and installation of engine front oil seal ........................................................................................................................................1675 Removal and installation of engine rear oil seal .........................................................................................................................................1678 Removal and installation of cooling fan and fan motor assembly ...........................................................................................................................1681 Removal and installation of KDPF assembly ................................................................................................................................................1683 Disassembly and assembly of KDPF assembly ................................................................................................................................................1686 Removal and installation of KCCV assembly ................................................................................................................................................1695 Removal and installation of air cleaner assembly .........................................................................................................................................1696 Removal and installation of KVGT assembly ................................................................................................................................................1697 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ...............................................................................................................1700 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ..............................................................................................................1702 Removal and installation of alternator belt ..............................................................................................................................................1704 Removal and installation of fuel tank assembly ...........................................................................................................................................1705 Power train ..................................................................................................................................................................................1708 Removal and installation of transfer assembly ............................................................................................................................................1708 Disassembly and assembly of transfer assembly ............................................................................................................................................1712 Removal and installation of front axle assembly ..........................................................................................................................................1743 Removal and installation of rear axle assembly ...........................................................................................................................................1745 Disassembly and assembly of axle housing assembly ........................................................................................................................................1748 Disassembly and assembly of differential assembly ........................................................................................................................................1760 Undercarriage and frame ......................................................................................................................................................................1782 Removal and installation of center hinge pin .............................................................................................................................................1782 Removal and installation of counterweight assembly .......................................................................................................................................1791 Hydraulic system .............................................................................................................................................................................1795 Removal and installation of hydraulic tank assembly ......................................................................................................................................1795 Removal and installation of control valve assembly .......................................................................................................................................1799 Disassembly and assembly of control valve assembly .......................................................................................................................................1803 Removal and installation of hydraulic pump assembly ......................................................................................................................................1806 Removal and installation of HST motor1 assembly ..........................................................................................................................................1811 Removal and installation of HST motor2 assembly ..........................................................................................................................................1813 Disassembly and assembly of hydraulic cylinder assembly ..................................................................................................................................1815 Work equipment ...............................................................................................................................................................................1822 Removal and installation of work equipment assembly ......................................................................................................................................1822 Cab and its attachments ......................................................................................................................................................................1828 Removal and installation of operator's cab and floor frame assembly ......................................................................................................................1828 Removal and installation of operator's cab glass (adhered glass) .........................................................................................................................1833 Removal and installation of operator's seat assembly .....................................................................................................................................1841 Removal and installation of seat belt ....................................................................................................................................................1843 Removal and installation of air conditioner unit assembly ................................................................................................................................1844 Removal and installation of air conditioner compressor ...................................................................................................................................1849 Removal and installation of air conditioner condenser ....................................................................................................................................1851 Electrical system ............................................................................................................................................................................1853 Removal and installation of machine monitor assembly .....................................................................................................................................1853 Removal and installation of engine controller assembly ...................................................................................................................................1855 Removal and installation of HST controller assembly ......................................................................................................................................1857 Removal and installation of air conditioner controller assembly ..........................................................................................................................1859 Removal and installation of monitor controller assembly ..................................................................................................................................1860 Removal and installation of mass air flow and temperature sensor .........................................................................................................................1862 Removal and installation of KOMTRAX terminal assembly ....................................................................................................................................1863 60 Maintenance standard ..........................................................................................................................................................................1865 Table of contents ............................................................................................................................................................................1866 Engine and cooling system ....................................................................................................................................................................1867 Engine related parts .....................................................................................................................................................................1867 Cooling fan motor ........................................................................................................................................................................1868 Power train ..................................................................................................................................................................................1870 Damper ...................................................................................................................................................................................1870 Transfer .................................................................................................................................................................................1871 Drive shaft ..............................................................................................................................................................................1878 Axle .....................................................................................................................................................................................1879 Differential .............................................................................................................................................................................1881 Limited slip differential ................................................................................................................................................................1885 Final drive ..............................................................................................................................................................................1887 Steering system ..............................................................................................................................................................................1889 Steering column ..........................................................................................................................................................................1889 Priority valve ...........................................................................................................................................................................1890 Emergency steering valve .................................................................................................................................................................1891 Steering cylinder ........................................................................................................................................................................1892 Brake system .................................................................................................................................................................................1894 Brake accumulator charge valve ...........................................................................................................................................................1894 Slack adjuster ...........................................................................................................................................................................1895 Brake ....................................................................................................................................................................................1896 Parking brake ............................................................................................................................................................................1898 Parking brake solenoid valve .............................................................................................................................................................1899 Undercarriage and frame ......................................................................................................................................................................1900 Axle mount ...............................................................................................................................................................................1900 Center hinge pin .........................................................................................................................................................................1902 Hydraulic system .............................................................................................................................................................................1905 Hydraulic tank ...........................................................................................................................................................................1905 Double type gear pump ....................................................................................................................................................................1906 Steering and work equipment pump .........................................................................................................................................................1907 Control valve ............................................................................................................................................................................1911 Self-pressure reducing valve .............................................................................................................................................................1924 Work equipment PPC valve .................................................................................................................................................................1926 Work equipment lock solenoid valve .......................................................................................................................................................1928 Work equipment ...............................................................................................................................................................................1929 Work equipment linkage ...................................................................................................................................................................1929 Bucket ...................................................................................................................................................................................1933 Work equipment cylinder ..................................................................................................................................................................1935 Cab and its attachments ......................................................................................................................................................................1936 Cab mount ................................................................................................................................................................................1936 Electrical system ............................................................................................................................................................................1937 Bucket positioner ........................................................................................................................................................................1937 Fork positioner ..........................................................................................................................................................................1938 Remote boom positioner ...................................................................................................................................................................1939 80 Appendix ......................................................................................................................................................................................1941 Table of contents ............................................................................................................................................................................1942 Air conditioner components ...................................................................................................................................................................1943 Precautions for refrigerant ..............................................................................................................................................................1943 Air conditioner component ................................................................................................................................................................1944 Configuration and function of refrigeration cycle ........................................................................................................................................1946 Outline of refrigeration cycle ...........................................................................................................................................................1947 Air conditioner unit .....................................................................................................................................................................1949 Dual pressure switch .....................................................................................................................................................................1954 Air conditioner controller ...............................................................................................................................................................1955 Compressor ...............................................................................................................................................................................1956 Condenser ................................................................................................................................................................................1957 Receiver drier ...........................................................................................................................................................................1958 Sunlight sensor ..........................................................................................................................................................................1960 Outer temperature sensor (outside air temperature sensor) ................................................................................................................................1961 Procedure for testing and troubleshooting ................................................................................................................................................1962 Circuit diagram and arrangement of connector pins ........................................................................................................................................1964 System diagram ...........................................................................................................................................................................1967 Parts and connectors layout ..............................................................................................................................................................1970 Testing with self-diagnosis function .....................................................................................................................................................1975 How to open the electrical system abnormality record screen in service mode of the machine monitor .......................................................................................1976 Testing temperature control system .......................................................................................................................................................1978 Testing vent (mode) changeover ...........................................................................................................................................................1980 Testing FRESH/RECIRC air changeover ......................................................................................................................................................1982 Testing evaporator temperature sensor ....................................................................................................................................................1984 Testing relays ...........................................................................................................................................................................1986 Troubleshooting chart 1 ..................................................................................................................................................................1988 Troubleshooting chart 2 ..................................................................................................................................................................1989 Information in troubleshooting table .....................................................................................................................................................1991 Failure code list related to air conditioner .............................................................................................................................................1992 Failure code [879AKA] A/C Inner Sensor Open Circuit ......................................................................................................................................1993 Failure code [879AKB] A/C Inner Sensor Short Circuit .....................................................................................................................................1995 Failure code [879BKA] A/C Outer Sensor Open Circuit ......................................................................................................................................1997 Failure code [879BKB] A/C Outer Sensor Short Circuit .....................................................................................................................................1999 Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................................................................................................2001 Failure code [879CKB] Ventilating Sensor Short Circuit ...................................................................................................................................2003 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..............................................................................................................................2005 Failure code [879EMC] Ventilation Damper Abnormality .....................................................................................................................................2007 Failure code [879FMC] Air Mix Damper Abnormality .........................................................................................................................................2010 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) .....................................................................................2013 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................................................................................................2016 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...................................................................................................2019 A-4 Troubleshooting for FRESH/RECIRC air changeover ......................................................................................................................................2022 Troubleshooting with gauge pressure ......................................................................................................................................................2024 Connection of service tool ...............................................................................................................................................................2027 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ..................................................................................................2029 Handling of compressor oil ...............................................................................................................................................................2031 90 Diagrams and drawings .........................................................................................................................................................................2033 Table of contents ............................................................................................................................................................................2034 Hydraulic circuit diagram ....................................................................................................................................................................2035 Symbols in hydraulic circuit diagram .....................................................................................................................................................2035 Hydraulic circuit diagram.................................................................................................................................................................2039 Electric circuit diagram .....................................................................................................................................................................2041 Symbols in electric circuit diagram ......................................................................................................................................................2041 Electrical circuit diagram of machine body ............................................................................................................................................... 0 Electrical circuit diagram of machine body (1/5)......................................................................................................................................2045 Electrical circuit diagram of machine body (2/5)......................................................................................................................................2046 Electrical circuit diagram of machine body (3/5)......................................................................................................................................2047 Electrical circuit diagram of machine body (4/5)......................................................................................................................................2048 Electrical circuit diagram of machine body (5/5)......................................................................................................................................2049 Electrical circuit diagram of floor ...................................................................................................................................................... 0 Electrical circuit diagram of floor (1/8).............................................................................................................................................2050 Electrical circuit diagram of floor (2/8).............................................................................................................................................2051 Electrical circuit diagram of floor (3/8).............................................................................................................................................2052 Electrical circuit diagram of floor (4/8).............................................................................................................................................2053 Electrical circuit diagram of floor (5/8).............................................................................................................................................2054 Electrical circuit diagram of floor (6/8).............................................................................................................................................2055 Electrical circuit diagram of floor (7/8).............................................................................................................................................2056 Electrical circuit diagram of floor (8/8).............................................................................................................................................2057 INDEX.............................................................................................................................................................................................2058
DESCRIPTION:
KOMATSU WA320-7 WHEEL LOADER SHOP MANUAL VENBM27500 – PDF DOWNLOAD
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 25/12/24
