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Komatsu WA380-7 Wheel Loader Shop Manual PDF Download
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KOMATSU WA380-7 Wheel Loader Service Repair Manual
- SERIAL NUMBERS: 10001 and up
- PUBLICATION NUMBER:SEN05650-03
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Description
KOMATSU WA380-7 Wheel Loader Service Repair Manual
KOMATSU WA380-7 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOTS OF THE MANUAL:
DESCRIPTION:
KOMATSU WA380-7 Wheel Loader Service Repair Manual
This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
This section includes the index, foreword, safety and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of the machine. The section of “Sthcture and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
The standard values for a new machine and trouble shooting are described. This standard value table is used fortesting and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
KOMATSU WA380-7 Wheel Loader Service Repair Manual
COVER.................................................................................................................................................... 1 00 Index and foreword ................................................................................................................................... 3 Index ............................................................................................................................................... 4 Foreword, safety and general information ............................................................................................................ 20 Important safety notice ......................................................................................................................... 20 How to read the shop manual ..................................................................................................................... 27 Explanation of terms for maintenance standard ................................................................................................... 29 Handling equipment of fuel system devices ....................................................................................................... 31 Handling of intake system parts ................................................................................................................. 32 Handling of hydraulic equipment ................................................................................................................. 33 Method of disconnecting and connecting of push-pull type coupler ................................................................................ 35 Handling of electrical equipment ................................................................................................................ 38 How to read electric wire code .................................................................................................................. 46 Precautions when performing operation ........................................................................................................... 49 Practical use of KOMTRAX ........................................................................................................................ 53 Standard tightening torque table ................................................................................................................ 54 List of abbreviation ............................................................................................................................ 58 Conversion table ................................................................................................................................ 63 01 Specification ........................................................................................................................................ 69 Table of contents ................................................................................................................................... 70 Specifications ...................................................................................................................................... 71 Specification drawing ........................................................................................................................... 71 Specification ................................................................................................................................... 73 Weight table .................................................................................................................................... 79 Table of fuel, coolant and lubricants ........................................................................................................... 81 10 Structure and function ............................................................................................................................... 83 Table of contents ................................................................................................................................... 84 Engine and cooling system ........................................................................................................................... 86 Engine related parts ............................................................................................................................ 86 KVGT ............................................................................................................................................ 88 EGR system piping drawing ....................................................................................................................... 95 EGR system circuit diagram ...................................................................................................................... 97 EGR valve ....................................................................................................................................... 99 EGR cooler ...................................................................................................................................... 101 KCCV layout drawing ............................................................................................................................. 102 KCCV ventilator ................................................................................................................................. 104 KDPF ............................................................................................................................................ 106 Cooling system .................................................................................................................................. 110 Cooling fan pump ................................................................................................................................ 113 Cooling fan motor ............................................................................................................................... 122 Power train ......................................................................................................................................... 130 Power train system .............................................................................................................................. 130 Drive shaft ..................................................................................................................................... 133 Power train piping drawing ...................................................................................................................... 134 Transmission control ............................................................................................................................ 135 Torque converter ................................................................................................................................ 137 Transmission .................................................................................................................................... 142 Transmission control valve ...................................................................................................................... 161 Forward and reverse clutch ECMV and gear speed clutch ECMV ...................................................................................... 164 Lockup clutch ECMV .............................................................................................................................. 171 Main relief and torque converter relief valve ................................................................................................... 175 Axle ............................................................................................................................................ 177 Differential .................................................................................................................................... 179 Limited slip differential ....................................................................................................................... 183 Final drive ..................................................................................................................................... 187 Steering system ..................................................................................................................................... 189 Layout of steering devices ...................................................................................................................... 189 Steering column ................................................................................................................................. 190 Steering pump ................................................................................................................................... 191 Steering valve .................................................................................................................................. 203 Orbit-roll valve ................................................................................................................................ 217 Stop valve ...................................................................................................................................... 223 Emergency steering motor ........................................................................................................................ 224 Emergency steering pump ......................................................................................................................... 225 Brake system ........................................................................................................................................ 226 Layout of brake parts ........................................................................................................................... 226 Charge valve .................................................................................................................................... 228 Brake valve ..................................................................................................................................... 234 Accumulator (for brake) ......................................................................................................................... 238 Brake ........................................................................................................................................... 239 Parking brake control ........................................................................................................................... 242 Parking brake ................................................................................................................................... 243 Parking brake solenoid valve .................................................................................................................... 244 Parking brake emergency release valve ........................................................................................................... 247 Undercarriage and frame ............................................................................................................................. 248 Axle mount and center hinge pin ................................................................................................................. 248 Tire ............................................................................................................................................ 249 Hydraulic system .................................................................................................................................... 251 Hydraulic component layout ...................................................................................................................... 251 Work equipment control .......................................................................................................................... 253 Hydraulic tank .................................................................................................................................. 255 Double type gear pump ........................................................................................................................... 257 Work equipment pump ............................................................................................................................. 258 Control valve ................................................................................................................................... 270 CLSS ............................................................................................................................................ 280 Hydraulic circuit diagram and name of valves .................................................................................................... 284 Accumulator charge valve ........................................................................................................................ 299 Stabilizer valve ................................................................................................................................ 303 Work equipment lock solenoid valve .............................................................................................................. 308 Accumulator (for PPC circuit) ................................................................................................................... 309 Accumulator (for ECSS) .......................................................................................................................... 310 Work equipment ...................................................................................................................................... 311 Work equipment linkage .......................................................................................................................... 311 Bucket .......................................................................................................................................... 312 Bucket positioner and boom positioner ........................................................................................................... 313 Cab and its attachments ............................................................................................................................. 314 ROPS cab ........................................................................................................................................ 314 Electrical system ................................................................................................................................... 315 Engine control system ........................................................................................................................... 315 Preheating system ............................................................................................................................... 317 Engine power mode selector circuit .............................................................................................................. 319 Engine output limit function .................................................................................................................... 320 Automatic warm-up function ...................................................................................................................... 321 Parking brake control system .................................................................................................................... 322 System operating lamp function .................................................................................................................. 324 Battery disconnect switch function .............................................................................................................. 326 Transmission controller system .................................................................................................................. 328 Work equipment control system ................................................................................................................... 363 Machine monitor system .......................................................................................................................... 384 Rear view monitor system ........................................................................................................................ 410 KOMTRAX system .................................................................................................................................. 413 System component parts .......................................................................................................................... 416 Sensor .......................................................................................................................................... 449 20 Standard value tables ................................................................................................................................ 471 Table of contents ................................................................................................................................... 472 Standard service value table ........................................................................................................................ 473 Standard value table for engine ................................................................................................................. 473 Standard value table for machine ................................................................................................................ 475 30 Testing and adjusting ................................................................................................................................ 489 Table of contents ................................................................................................................................... 490 General information on testing and adjusting ........................................................................................................ 492 Tools for testing and adjusting ................................................................................................................. 492 Sketch of tools for testing and adjusting ....................................................................................................... 497 Engine and cooling system ........................................................................................................................... 498 Testing engine speed ............................................................................................................................ 498 Measuring boost pressure ........................................................................................................................ 499 Testing exhaust gas temperature ................................................................................................................. 501 Testing exhaust gas color ....................................................................................................................... 503 Testing and adjusting valve clearance ........................................................................................................... 505 Measuring compression pressure .................................................................................................................. 507 Testing blowby pressure ......................................................................................................................... 511 Testing engine oil pressure ..................................................................................................................... 513 Testing EGR valve and KVGT driving oil pressure ................................................................................................. 514 Testing fuel pressure ........................................................................................................................... 515 Testing fuel delivery, return and leakage ....................................................................................................... 520 Bleeding air from fuel system ................................................................................................................... 526 Testing fuel circuit for leakage ................................................................................................................ 528 Handling cylinder cutout mode operation ......................................................................................................... 529 Handling no injection cranking operation ........................................................................................................ 530 Testing of KDPF and muffler stack for looseness and damage ...................................................................................... 531 Testing of installed condition of cylinder head and manifolds ................................................................................... 532 Testing engine piping for damage and looseness .................................................................................................. 533 Testing and adjusting air conditioner compressor belt tension ................................................................................... 534 Replacing alternator belt ....................................................................................................................... 535 Power train ......................................................................................................................................... 536 Adjusting transmission output speed sensor ...................................................................................................... 536 Adjusting transmission input speed sensor ....................................................................................................... 537 Flushing procedure for torque converter and transmission hydraulic circuit ...................................................................... 538 Retrieval of disabled machine due to transmission valve failure ................................................................................. 539 Checking oil leakage from axle final drive ...................................................................................................... 541 Testing drive shaft for looseness, backlash, and damage ......................................................................................... 542 Testing and adjusting power train oil pressure .................................................................................................. 543 Steering system ..................................................................................................................................... 558 Testing directional lever ....................................................................................................................... 558 Testing steering wheel .......................................................................................................................... 559 Testing work equipment control lever ............................................................................................................ 561 Testing and adjusting steering circuit pressure ................................................................................................. 563 Bleeding air from steering cylinder circuit. .................................................................................................... 566 Testing and adjusting steering stopper valve .................................................................................................... 567 Brake system ........................................................................................................................................ 568 Testing brake pedal ............................................................................................................................. 568 Testing and adjusting brake pedal linkage ....................................................................................................... 569 Testing braking performance ..................................................................................................................... 570 Measuring accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas ................................................. 571 Testing and adjusting of accumulator charge pressure ............................................................................................ 575 Testing wheel brake oil pressure ................................................................................................................ 577 Testing lowering of wheel brake pressure ........................................................................................................ 578 Measuring wear of wheel brake disc .............................................................................................................. 581 Bleeding air from wheel brake circuit ........................................................................................................... 582 Releasing remaining pressure in brake accumulator circuit ....................................................................................... 583 Testing parking brake performance ............................................................................................................... 584 Testing parking brake oil pressure .............................................................................................................. 585 Testing wear of parking brake disc .............................................................................................................. 587 Method of releasing parking brake manually ...................................................................................................... 588 Hydraulic system .................................................................................................................................... 589 Checking fan speed .............................................................................................................................. 589 Measuring fan pump circuit oil pressure ......................................................................................................... 590 Bleeding air from hydraulic fan circuit ......................................................................................................... 591 Testing and adjusting work equipment PPC oil pressure ........................................................................................... 592 Testing and adjusting work equipment oil pressure ............................................................................................... 595 Bleeding air from work equipment circuit ........................................................................................................ 599 Releasing remaining pressure from work equipment circuit ........................................................................................ 600 Checking of E.C.S.S. accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ................................. 601 Work equipment ...................................................................................................................................... 605 Testing and adjusting bucket position detection lever ........................................................................................... 605 Testing and adjusting boom position detection lever ............................................................................................. 606 Electrical system ................................................................................................................................... 607 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor .......................................................... 607 Special functions of machine monitor ............................................................................................................ 609 Angle adjustment of rear view camera ............................................................................................................ 703 Handling voltage circuit of engine controller ................................................................................................... 704 Handling battery disconnect switch .............................................................................................................. 705 Testing diodes .................................................................................................................................. 706 Pm clinic ........................................................................................................................................... 707 Pm Clinic service ............................................................................................................................... 707 Check sheet ..................................................................................................................................... 708 40 Troubleshooting ...................................................................................................................................... 713 Table of contents ................................................................................................................................... 714 General information on troubleshooting .............................................................................................................. 724 Troubleshooting points .......................................................................................................................... 724 Sequence of events in troubleshooting ........................................................................................................... 726 Check before troubleshooting .................................................................................................................... 728 Inspection procedure before troubleshooting ..................................................................................................... 730 Preparation work for troubleshooting of electrical system ....................................................................................... 747 Classification and procedures for troubleshooting ............................................................................................... 753 Symptom and troubleshooting numbers ............................................................................................................. 756 Information in troubleshooting table ............................................................................................................ 759 Connector list and layout ....................................................................................................................... 761 T-branch box and T-branch adapter table ......................................................................................................... 777 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ......................................................... 783 Fuse location table ............................................................................................................................. 786 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................................................................... 789 Precautions on troubleshooting of machine monitor ............................................................................................... 792 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ......................................................... 794 Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................................. 799 Fabrication of short-circuit connector (for CA1883 and CA3135) .................................................................................. 800 Failure codes table ............................................................................................................................. 801 Troubleshooting by failure code (Display of code) ................................................................................................... 815 Failure code [1500L0] Double Engagement of T/M Clutches ......................................................................................... 815 Failure code [15SAL1] Release Trouble of ECMV (Forward) ......................................................................................... 816 Failure code [15SALH] Malfunction of ECMV (Forward) ............................................................................................. 818 Failure code [15SBL1] Release Trouble of ECMV (Reverse) ......................................................................................... 820 Failure code [15SBLH] Malfunction of ECMV (Reverse) ............................................................................................. 822 Failure code [15SEL1] Release Trouble of ECMV (1st) ............................................................................................. 824 Failure code [15SELH] Malfunction of ECMV (1st) ................................................................................................. 826 Failure code [15SFL1] Release Trouble of ECMV (2nd) ............................................................................................. 828 Failure code [15SFLH] Malfunction of ECMV (2nd) ................................................................................................. 830 Failure code [15SGL1] Release Trouble of ECMV (3rd) ............................................................................................. 832 Failure code [15SGLH] Malfunction of ECMV (3rd) ................................................................................................. 834 Failure code [15SHL1] Release Trouble of ECMV (4th) ............................................................................................. 836 Failure code [15SHLH] Malfunction of ECMV (4th) ................................................................................................. 838 Failure code [2F00MA] Failure of Parking Brake Circuit .......................................................................................... 840 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...................................................................................... 843 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....................................................................................... 845 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................................. 847 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................ 848 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................................. 849 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................ 850 Failure code [879CKA] Ventilating Sensor Open Circuit ........................................................................................... 851 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................................................... 852 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..................................................................................... 853 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................ 854 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................ 855 Failure code [989A00] Engine Overrun Prevention Activated ....................................................................................... 856 Failure code [989L00] Engine Controller Lock Caution 1 .......................................................................................... 857 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................................... 858 Failure code [989N00] Engine Controller Lock Caution 3 .......................................................................................... 859 Failure code [A1U0N3] HC Desorb Request 1 ....................................................................................................... 860 Failure code [A1U0N4] HC Desorb Request 2 ....................................................................................................... 862 Failure code [AA10NX] Air Cleaner Clogging ...................................................................................................... 864 Failure code [B@BAZG] Eng Oil Press Low ......................................................................................................... 866 Failure code [B@BAZK] Engine Oil Level Low ...................................................................................................... 867 Failure code [B@BCNS] Eng Water Overheat ........................................................................................................ 868 Failure code [B@BCZK] Eng Water Level Low ....................................................................................................... 869 Failure code [B@CENS] T/C Oil Temp. Overheat .................................................................................................... 871 Failure code [B@HANS] HYD Oil Temp. Overheat .................................................................................................... 872 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................................... 873 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................................ 874 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................................. 876 Failure code [CA131] Throttle Sensor High Error ................................................................................................. 878 Failure code [CA132] Throttle Sensor Low Error .................................................................................................. 880 Failure code [CA144] Coolant Temp Sens High Error ............................................................................................... 882 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................................ 884 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................................. 886 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................................. 888 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................................. 890 Failure code [CA221] Ambient Press Sens High Error .............................................................................................. 892 Failure code [CA222] Ambient Press Sens Low Error ............................................................................................... 894 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................................ 896 Failure code [CA234] Eng Overspeed .............................................................................................................. 897 Failure code [CA238] Ne Speed Sensor Supply Volt Error .......................................................................................... 898 Failure code [CA239] Ne Speed Sens Supply Volt High Error ....................................................................................... 899 Failure code [CA271] IMV/PCV1 Short Error ....................................................................................................... 900 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................................ 902 Failure code [CA295] Ambient Press Sens In Range Error .......................................................................................... 904 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................................................... 905 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................................................... 907 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................................................... 909 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................................................... 911 Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................................................... 913 Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................................................... 915 Failure code [CA343] ECM Critical Internal Failure .............................................................................................. 917 Failure code [CA351] Injectors Drive Circuit Error .............................................................................................. 918 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................................. 919 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................................ 921 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................................. 923 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................................ 925 Failure code [CA428] Water in Fuel Sensor High Error ............................................................................................ 926 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................................. 928 Failure code [CA431] Idle Validation Sw Error ................................................................................................... 930 Failure code [CA432] Idle Validation Process Error .............................................................................................. 933 Failure code [CA435] Eng Oil Press Sw Error ..................................................................................................... 936 Failure code [CA441] Battery Voltage Low Error .................................................................................................. 937 Failure code [CA442] Battery Voltage High Error ................................................................................................. 939 Failure code [CA449] Rail Press Very High Error ................................................................................................. 940 Failure code [CA451] Rail Press Sensor High Error ............................................................................................... 941 Failure code [CA452] Rail Press Sensor Low Error ................................................................................................ 943 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................................ 945 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................................ 946 Failure code [CA516] Rail Press Sens Sup Volt Low Error ......................................................................................... 948 Failure code [CA553] Rail Press High Error ...................................................................................................... 950 Failure code [CA555] Crankcase Press High Error 1 ............................................................................................... 951 Failure code [CA556] Crankcase Press High Error 2 ............................................................................................... 952 Failure code [CA559] Rail Press Low Error ....................................................................................................... 953 Failure code [CA595] Turbo Speed High Error 2 ................................................................................................... 955 Failure code [CA687] Turbo Speed Low Error ...................................................................................................... 956 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................................. 958 Failure code [CA691] Intake Air Temp Sens High Error ............................................................................................ 960 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................................. 962 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................................ 964 Failure code [CA698] ECM Int Temp Sensor Low Error .............................................................................................. 965 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................................ 966 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................................ 968 Failure code [CA1117] Persistent Data Lost Error ................................................................................................ 973 Failure code [CA1664] KDOC Malfunction .......................................................................................................... 974 Failure code [CA1691] Regeneration Ineffective .................................................................................................. 977 Failure code [CA1695] Sensor 5 Supply Volt High Error ........................................................................................... 980 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................................................ 981 Failure code [CA1843] Crankcase Press Sens High Error ........................................................................................... 983 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................................................ 985 Failure code [CA1879] KDPF Delta P Sensor High Error ............................................................................................ 987 Failure code [CA1881] KDPF Delta P Sensor Low Error ............................................................................................. 989 Failure code [CA1883] KDPF Delta P Sens In Range Error .......................................................................................... 991 Failure code [CA1921] KDPF Soot Load High Error 1 ............................................................................................... 996 Failure code [CA1922] KDPF Soot Load High Error 2 ............................................................................................... 999 Failure code [CA1942] Crankcase Press Sens In Range Error .......................................................................................1003 Failure code [CA1993] KDPF Delta Pressure Low Error .............................................................................................1004 Failure code [CA2185] Throt Sensor Sup Volt High Error ..........................................................................................1007 Failure code [CA2186] Throt Sensor Sup Volt Low Error ...........................................................................................1009 Failure code [CA2249] Rail Press Very Low Error .................................................................................................1011 Failure code [CA2271] EGR Valve Pos Sens High Error .............................................................................................1012 Failure code [CA2272] EGR Valve Pos Sens Low Error ..............................................................................................1014 Failure code [CA2288] Turbo Speed High Error 1 ..................................................................................................1017 Failure code [CA2311] IMV Solenoid Error ........................................................................................................1018 Failure code [CA2349] EGR Valve Solenoid Open Error .............................................................................................1019 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................................1021 Failure code [CA2357] EGR Valve Servo Error .....................................................................................................1023 Failure code [CA2373] Exhaust Manifold Press Sens High error ....................................................................................1024 Failure code [CA2374] Exhaust Manifold Press Sens Low error .....................................................................................1026 Failure code [CA2375] EGR Orifice Temp Sens High Error ..........................................................................................1028 Failure code [CA2376] EGR Orifice Temp Sens Low Error ...........................................................................................1030 Failure code [CA2381] KVGT Pos Sens High Error ..................................................................................................1032 Failure code [CA2382] KVGT Pos Sens Low Error ...................................................................................................1034 Failure code [CA2383] KVGT Solenoid Open Error ..................................................................................................1037 Failure code [CA2386] KVGT Solenoid Short Error .................................................................................................1039 Failure code [CA2387] KVGT Servo Error ..........................................................................................................1041 Failure code [CA2554] Exh Manifold Press Sens In Range Error ....................................................................................1042 Failure code [CA2555] Grid Htr Relay Volt Low Error .............................................................................................1043 Failure code [CA2556] Grid Htr Relay Volt High Error ............................................................................................1045 Failure code [CA2637] KDOC Face Plugging ........................................................................................................1047 Failure code [CA2639] Manual Stationary Regeneration Request ....................................................................................1049 Failure code [CA2961] EGR Orifice Temp High Error 1 .............................................................................................1052 Failure code [CA2973] Chg Air Press Sensor In Range Error .......................................................................................1053 Failure code [CA3133] KDPF Outlet Press Sens High Error .........................................................................................1054 Failure code [CA3134] KDPF Outlet Press Sens Low Error ..........................................................................................1056 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .....................................................................................1058 Failure code [CA3251] KDOC Inlet Temp High Error ................................................................................................1062 Failure code [CA3253] KDOC Temp Error - Non Regeneration ........................................................................................1065 Failure code [CA3254] KDOC Outlet Temp High Error 1 .............................................................................................1068 Failure code [CA3255] KDPF Temp Error - Non Regeneration ........................................................................................1071 Failure code [CA3256] KDPF Outlet Temp High Error 1 .............................................................................................1074 Failure code [CA3311] KDOC Outlet Temp High Error 2 .............................................................................................1077 Failure code [CA3312] KDPF Outlet Temp High Error 2 .............................................................................................1080 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ..........................................................................................1083 Failure code [CA3314] KDOC Inlet Temp Sens High Error ...........................................................................................1086 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .......................................................................................1090 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...........................................................................................1095 Failure code [CA3317] KDOC Outlet Temp Sens High Error ..........................................................................................1098 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ......................................................................................1102 Failure code [CA3319] KDPF Outlet Temp Sens High Error ..........................................................................................1107 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...........................................................................................1111 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ......................................................................................1114 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ..................................................................................1118 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...................................................................................1120 Failure code [CA3741] Rail Press Valve Trip Error ...............................................................................................1122 Failure code [D150KA] Disconnection of Emerg. Steering Relay ....................................................................................1123 Failure code [D150KB] Ground Fault of Emerg. Steering Relay .....................................................................................1125 Failure code [D150KY] Hot Short of Emergency Steering Relay .....................................................................................1127 Failure code [D160KA] Disconnection of Backup Lamp Relay Output .................................................................................1129 Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ..................................................................................1131 Failure code [D160KY] Hot Short of Backup Lamp Relay Output .....................................................................................1133 Failure code [D191KA] Disconnection of Neutral Output Relay .....................................................................................1135 Failure code [D191KB] Ground Fault of Neutral Output Relay ......................................................................................1138 Failure code [D191KY] Hot Short of Neutral Output Relay .........................................................................................1141 Failure code [D192KA] Disconnection of ECSS Solenoid ............................................................................................1143 Failure code [D192KB] Ground Fault of ECSS Solenoid .............................................................................................1145 Failure code [D192KY] Hot Short of ECSS Solenoid ................................................................................................1146 Failure code [D19JKZ] Personal Code Relay Abnormality ...........................................................................................1147 Failure code [D1E6KA] Disconnection of Parking Brake Relay ......................................................................................1149 Failure code [D1E6KB] Ground Fault of Parking Brake Relay .......................................................................................1151 Failure code [D1E6KY] Hot Short of Parking Brake Relay ..........................................................................................1153 Failure code [D5ZHKA] Failure of Key SW C Signal ................................................................................................1155 Failure code [D5ZHKB] Key SW C Signal Short Circuit .............................................................................................1157 Failure code [D5ZHKZ] Failure of Key SW C Signal ................................................................................................1159 Failure code [D5ZHL6] Disconnection of Key SW C .................................................................................................1161 Failure code [D811MC] KOMTRAX Error .............................................................................................................1163 Failure code [D862KA] GPS Antenna Open Circuit ..................................................................................................1164 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .....................................................................................1165 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ....................................................................................1167 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...................................................................................................1169 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .....................................................................................................1170 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................................................................1171 Failure code [DAF0MB] Monitor ROM Abnormality ...................................................................................................1172 Failure code [DAF0MC] Monitor Error .............................................................................................................1173 Failure code [DAF3KK] Controller Power Source Low (MON) .........................................................................................1174 Failure code [DAF8KB] Camera Power Supply Short Circuit .........................................................................................1176 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ....................................................................................1177 Failure code [DAFGMC] GPS Module Error ..........................................................................................................1179 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) .........................................................................................1180 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ........................................................................................1182 Failure code [DAFQKR] CAN2 Discon (Monitor) .....................................................................................................1184 Failure code [DAQ0KK] Controller Power Source Low (T/M) .........................................................................................1185 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ..................................................................................1188 Failure code [DAQ0MC] T/M Con Error .............................................................................................................1189 Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .........................................................................................1190 Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ...........................................................................................1192 Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ...................................................................................1195 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ....................................................................................1197 Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) .........................................................................................1198 Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ........................................................................................1200 Failure code [DAQQKR] CAN2 Discon (Transmission Con) ............................................................................................1202 Failure code [DAQRKR] CAN1 Discon (Transmission Con) ............................................................................................1203 Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ...................................................................................1204 Failure code [DAZ9KQ] A/C Model Selection Abnormality ...........................................................................................1205 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ..................................................................................................1206 Failure code [DB2QKR] CAN2 Discon (Engine Con) ..................................................................................................1207 Failure code [DB2RKR] CAN1 Discon (Engine Con) ..................................................................................................1212 Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................................................................1218 Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ..................................................................................1220 Failure code [DB90MC] BBC Error .................................................................................................................1221 Failure code [DB91KA] Disconnection of Key SW ACC (BBC) .........................................................................................1222 Failure code [DB92KK] Solenoid Power Source Low (BBC) ...........................................................................................1224 Failure code [DB95KX] Failure of 5 V Power Source 1 .............................................................................................1226 Failure code [DB96KX] Failure of 5 V Power Source 2 .............................................................................................1230 Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ....................................................................................1234 Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) .........................................................................................1235 Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ........................................................................................1237 Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .............................................................................................1239 Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .............................................................................................1240 Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ...................................................................................1241 Failure code [DBE5KX] Failure of 5 V Power Source ...............................................................................................1242 Failure code [DBE6KX] Failure of 24 V Power Source ..............................................................................................1244 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................................................................1246 Failure code [DDAAL6] Discon Engine Shutdown Secondary Switch ...................................................................................1250 Failure code [DDB6L4] Neutral Signal Malfunction ................................................................................................1252 Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ...................................................................................1255 Failure code [DDK3KA] FNR SW Input Signal Disconnection .........................................................................................1259 Failure code [DDK3KB] FNR SW Input Signal Short Circuit .........................................................................................1264 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ......................................................................................1268 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ......................................................................................1271 Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................................................................1273 Failure code [DDT0L4] Failure of Shift Mode Select SW ...........................................................................................1277 Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal .................................................................................1281 Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal .....................................................................................1285 Failure code [DDW9LD] Ground Fault of Kickdown Switch ...........................................................................................1289 Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW .........................................................................................1293 Failure code [DF10KA] Disconnection of Shift Lever Input ........................................................................................1297 Failure code [DF10KB] Ground Fault of Shift Lever Input .........................................................................................1299 Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor .....................................................................................1302 Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ......................................................................................1304 Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ......................................................................................1306 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ....................................................................................1308 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .........................................................................................1309 Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor .....................................................................................1311 Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ......................................................................................1313 Failure code [DH21KA] Failure of Loader Pump Press. Sensor ......................................................................................1315 Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ...................................................................................1317 Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit .....................................................................................1319 Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor .................................................................................1321 Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ...................................................................................1323 Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor .................................................................................1325 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .................................................................................1327 Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ................................................................................1330 Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ....................................................................................1332 Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit .................................................................................1334 Failure code [DHT8ZG] Steering Oil Pressure Low .................................................................................................1336 Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ...................................................................................1337 Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ....................................................................................1339 Failure code [DJF1KA] Disconnection of Fuel Level Sensor ........................................................................................1341 Failure code [DK55KA] Failure of FNR Lever Potentio .............................................................................................1343 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...................................................................................1346 Failure code [DK55L5] Failure of FNR Lever Potentio .............................................................................................1348 Failure code [DK59KA] Failure of Boom Lever Potentio (Main) .....................................................................................1349 Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ...................................................................................1355 Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................................................................1360 Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ......................................................................................1367 Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ....................................................................................1373 Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ...................................................................................1378 Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) .................................................................................1383 Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................................................................1388 Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ....................................................................................1395 Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ..................................................................................1400 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ......................................................................................1405 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ....................................................................................1410 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ..................................................................................1414 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) .......................................................................................1420 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) .....................................................................................1425 Failure code [DK5KKA] Failure of 4th Lever Potentio (Main) ......................................................................................1429 Failure code [DK5KKY] Hot Short of 4th Lever Potentio (Main) ....................................................................................1434 Failure code [DK5KL8] 4th Lever Potentio (Main & Sub) Disagree ..................................................................................1438 Failure code [DK5LKA] Failure of 4th Lever Potentio (Sub) .......................................................................................1444 Failure code [DK5LKY] Hot Short of 4th Lever Potentio (Sub) .....................................................................................1449 Failure code [DKA0KA] Failure of Boom Angle Sensor ..............................................................................................1453 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ....................................................................................1455 Failure code [DKA0L0] Boom Angle Sensor Dislocation .............................................................................................1457 Failure code [DKA1KA] Failure of Bucket Angle Sensor ............................................................................................1459 Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ..................................................................................1462 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ...................................................................................1464 Failure code [DLF1LC] Failure of T/M Input Speed Sensor .........................................................................................1466 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ................................................................................1468 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ......................................................................................1470 Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ................................................................................1472 Failure code [DLT3LC] Failure of Output Speed Sensor (Main) .....................................................................................1474 Failure code [DPQ1KR] LIN Discon (Switch Panel) .................................................................................................1476 Failure code [DPQ2KR] LIN Discon (LED Unit) .....................................................................................................1479 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ............................................................................................1482 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ..................................................................................................1485 Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .....................................................................................1486 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...................................................................................1490 Failure code [DV00KB] Ground Fault of Buzzer Output .............................................................................................1494 Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................................................................1496 Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) .................................................................................1498 Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................................................................1500 Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ................................................................................1502 Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) .................................................................................1504 Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ....................................................................................1506 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...................................................................................1508 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ................................................................................1510 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...................................................................................1512 Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ...................................................................................1514 Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................................................................1516 Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ...................................................................................1518 Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid .....................................................................................1520 Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ....................................................................................1521 Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. .......................................................................................1523 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ....................................................................................1524 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid .....................................................................................1526 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ........................................................................................1528 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................................................................1530 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ....................................................................................1534 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) .......................................................................................1538 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) .................................................................................1542 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ..................................................................................1546 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) .....................................................................................1550 Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ...................................................................................1554 Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................................................................1556 Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ...................................................................................1558 Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid .................................................................................1560 Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ..................................................................................1562 Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid .....................................................................................1564 Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...................................................................................1565 Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ................................................................................1567 Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid ...................................................................................1569 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ...................................................................................1570 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................................................................1572 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .......................................................................................1574 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ......................................................................................1576 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) .......................................................................................1578 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ..........................................................................................1580 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ......................................................................................1582 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .......................................................................................1584 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ..........................................................................................1586 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ......................................................................................1588 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) .......................................................................................1589 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ..........................................................................................1591 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ..................................................................................1593 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ...................................................................................1595 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ......................................................................................1597 Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ..................................................................................1599 Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ...................................................................................1600 Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ......................................................................................1602 Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ......................................................................................1604 Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) .......................................................................................1606 Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ..........................................................................................1608 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...................................................................................1610 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ....................................................................................1612 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .......................................................................................1614 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................................................................1616 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ....................................................................................1618 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) .......................................................................................1620 Failure code [DXJEKA] Disconnection of 4th EPC Solenoid (EXT) ...................................................................................1622 Failure code [DXJEKB] Ground Fault of 4th EPC Solenoid (EXT) ....................................................................................1624 Failure code [DXJEKY] Hot Short of 4th EPC Solenoid (EXT) .......................................................................................1626 Failure code [DXJFKA] Disconnection of 4th EPC Solenoid (RET) ...................................................................................1628 Failure code [DXJFKB] Ground Fault of 4th EPC Solenoid (RET) ....................................................................................1630 Failure code [DXJFKY] Hot Short of 4th EPC Solenoid (RET) .......................................................................................1632 Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor ....................................................................................1634 Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor ....................................................................................1637 Failure code [DY30ME] Emerg. Steering Long-Time Activated .......................................................................................1641 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ......................................................................................1643 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ....................................................................................1646 Failure code [LA00L3] Failure of Fan Reverse ....................................................................................................1648 Troubleshooting of electrical system (E-mode) .......................................................................................................1649 E-1 Engine does not start .......................................................................................................................1649 E-2 Manual preheating system does not work ......................................................................................................1656 E-3 Automatic preheating system does not work ...................................................................................................1659 E-4 While preheating is working, preheating monitor does not light up ...........................................................................1661 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ................................................................1663 E-6 LCD unit on machine monitor displays nothing ................................................................................................1666 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) .......................................................1668 E-8 LCD on machine monitor does not display properly ............................................................................................1670 E-9 Meter unit display on machine monitor is abnormal ...........................................................................................1672 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...........................................................................1675 E-11 Caution LED on machine monitor is abnormal .................................................................................................1678 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...................................................1680 E-13 Two switches operation of switch panel on machine monitor does not function ................................................................1682 E-14 Switch panel buzzer of machine monitor is abnormal .........................................................................................1685 E-15 Rear view monitor does not light up or backlight flickers ..................................................................................1687 E-16 Rear view monitor images are not displayed clearly .........................................................................................1690 E-17 Rear view monitor brightness cannot be adjusted ............................................................................................1693 E-18 Night lighting lamp of rear view monitor is abnormal .......................................................................................1696 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly .......................................................1698 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position .........................................1699 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ..............................................1703 E-22 Air cleaner clogging indicator lamp does not light .........................................................................................1705 E-23 Radiator coolant level caution lamp does not light .........................................................................................1706 E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ..................1708 E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ....1710 E-26 Fuel level gauge does not indicate correct level ...........................................................................................1711 E-27 Seat belt caution lamp indication is abnormal ..............................................................................................1713 E-28 Horn does not sound ........................................................................................................................1714 E-29 Horn does not stop sounding ................................................................................................................1717 E-30 Alarm buzzer does not sound ................................................................................................................1719 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................................................................1720 E-32 Kickdown does not work when kickdown switch is turned ON ...................................................................................1721 E-33 The hold switch does not work when it is pressed ...........................................................................................1723 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 ..............1725 E-35 Transmission cut-off mode is not selected or not released ..................................................................................1728 E-36 Transmission cut-off setting cannot be released ............................................................................................1730 E-37 Directional selector (FNR) switch mode is not selected or not released .....................................................................1732 E-38 When operating engine power selection switch, engine power selection function does not operate properly ....................................1734 E-39 Flow of loader pump does not increase from the minimum rate ................................................................................1736 E-40 ECSS function cannot be selected or cannot be released .....................................................................................1737 E-41 None of headlamp, clearance lamp, and tail lamp lights .....................................................................................1739 E-42 Clearance lamp and tail lamp do not light up or go out .....................................................................................1741 E-43 Both "High and Low beams" of headlamp do not light up or go out ............................................................................1744 E-44 The headlamp "Low beam" does not light up or go out ........................................................................................1748 E-45 The headlamp "High beam" does not light up or go out .......................................................................................1750 E-46 Front working lamp does not light up or go out .............................................................................................1752 E-47 Rear working lamp does not light up or go out ..............................................................................................1755 E-48 All of turn signal lamps and hazard lamps do not light up or go out ........................................................................1758 E-49 Turn signal lamps do not light up or go out ................................................................................................1761 E-50 Hazard lamp does not light up or go out ....................................................................................................1764 E-51 Brake lamp does not light up or stays lighted ..............................................................................................1767 E-52 Backup lamp does not light or continues to light ...........................................................................................1770 E-53 Backup buzzer does not sound or continues to sound .........................................................................................1773 E-54 Front wiper does not operate ...............................................................................................................1775 E-55 Rear wiper does not operate ................................................................................................................1778 E-56 Window washer does not operate .............................................................................................................1780 E-57 KOMTRAX system does not operate properly ...................................................................................................1783 Troubleshooting of hydraulic and mechanical system (H-mode) .........................................................................................1785 Information described in troubleshooting table (H-mode) .........................................................................................1785 System chart of hydraulic and mechanical systems ................................................................................................1786 Failure mode and cause table ....................................................................................................................1788 H-1 Machine does not start ......................................................................................................................1794 H-2 Torque converter lockup clutch is not disengaged (engine stalls) ............................................................................1797 H-3 Torque converter lockup clutch is not engaged ...............................................................................................1798 H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift .........................................1799 H-5 Large shock is made when machine starts or gear is shifted ..................................................................................1802 H-6 Machine starts or gear speed shifts with long time lag ......................................................................................1805 H-7 Torque converter oil temperature is high ....................................................................................................1807 H-8 Machine does not turn .......................................................................................................................1810 H-9 Turning response is poor ....................................................................................................................1812 H-10 Steering wheel is heavy to turn ............................................................................................................1814 H-11 Machine sways or large shocks are made while machine turns .................................................................................1815 H-12 Turning radius differs between right and left turns ........................................................................................1817 H-13 Wheel brakes do not work or are weak .......................................................................................................1818 H-14 Wheel brakes are not released or drag ......................................................................................................1819 H-15 Parking brake does not work or it is weak ..................................................................................................1820 H-16 Parking brake is not released or drags (including emergency release system) ................................................................1821 H-17 Boom does not rise .........................................................................................................................1822 H-18 Boom moves slow or boom lacks lifting force ................................................................................................1824 H-19 Rising boom slows down at certain height ...................................................................................................1826 H-20 Lift cylinders do not serve to hold bucket on ground .......................................................................................1827 H-21 Hydraulic drift of boom is large ...........................................................................................................1828 H-22 Boom moves up and down during operation ....................................................................................................1829 H-23 Bucket does not tilt back ..................................................................................................................1830 H-24 Bucket moves slow or bucket lacks tilt-back force ..........................................................................................1832 H-25 Bucket decelerates during tilt-back operation ..............................................................................................1834 H-26 Bucket cylinder does not hold bucket on ground .............................................................................................1835 H-27 Hydraulic drift of bucket is large .........................................................................................................1836 H-28 Bucket tilts back and forth during carrying load (work equipment valve in "HOLD") ..........................................................1837 H-29 Boom and bucket control levers do not move smoothly and heavy to move ......................................................................1838 H-30 Operating work equipment causes engine speed to lower significantly or engine to stall .....................................................1840 H-31 Large shocks are made when work equipment starts to move and stops .........................................................................1841 H-32 When certain work equipment stalls hydraulically, other work equipment moves ...............................................................1843 H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces .....................................................................1844 H-34 Air conditioner does not work while cooling fan rotates in reverse mode ....................................................................1845 H-35 Fan speed is abnormal (too high or low, or fan doe not rotate) .............................................................................1846 H-36 Unusual noise is heard from around fan .....................................................................................................1847 Troubleshooting of engine (S-mode) ..................................................................................................................1848 Information described in troubleshooting table (S mode) .........................................................................................1848 S-1 Engine does not crank when starting switch is turned to "START" position ....................................................................1849 S-2 Engine cranks but no exhaust smoke comes out ................................................................................................1850 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ..............................................1851 S-4 Engine startability is poor .................................................................................................................1852 S-5 Engine does not pick up smoothly ............................................................................................................1854 S-6 Engine stops during operation ...............................................................................................................1856 S-7 Engine runs rough or is unstable ............................................................................................................1858 S-8 Engine lacks power ..........................................................................................................................1859 S-9 Exhaust smoke is black (KDPF gets clogged in a short time) ..................................................................................1861 S-10 Engine oil consumption is excessive ........................................................................................................1863 S-11 Engine oil becomes contaminated early ......................................................................................................1864 S-12 Fuel consumption is excessive ..............................................................................................................1865 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...........................................................................1866 S-14 Oil pressure drops .........................................................................................................................1867 S-15 Fuel mixes into engine oil .................................................................................................................1868 S-16 Water mixes into engine oil (milky) ........................................................................................................1869 S-17 Coolant temperature rises too high (overheating) ...........................................................................................1870 S-18 Unusual noise is heard .....................................................................................................................1871 S-19 Vibration is excessive .....................................................................................................................1872 S-20 Air cannot be bled from fuel circuit .......................................................................................................1873 S-21 Active regeneration is executed frequently .................................................................................................1874 S-22 Active regeneration takes time .............................................................................................................1875 S-23 White smoke is exhausted during active regeneration ........................................................................................1876 50 Disassembly and assembly .............................................................................................................................1877 Table of contents ...................................................................................................................................1878 General information on disassembly and assembly .....................................................................................................1880 How to read this manual .........................................................................................................................1880 Coating materials list ..........................................................................................................................1882 Special tools list ..............................................................................................................................1886 Sketches of special tools .......................................................................................................................1889 Engine and cooling system ...........................................................................................................................1896 Removal and installation of supply pump assembly ................................................................................................1896 Removal and installation of injector assembly ...................................................................................................1899 Removal and installation of cylinder head assembly ..............................................................................................1910 Removal and installation of engine hood assembly ................................................................................................1929 Removal and installation of grille assembly .....................................................................................................1932 Removal and installation of cooling system assembly .............................................................................................1933 Removal and installation of radiator core assembly ..............................................................................................1936 Removal and installation of aftercooler .........................................................................................................1939 Removal and installation of hydraulic oil cooler assembly .......................................................................................1941 Removal and installation of fuel cooler assembly ................................................................................................1942 Removal and installation of engine, torque converter and transmission assemblies ................................................................1943 Disconnection and connection of engine, torque converter and transmission assembly ..............................................................1950 Removal and installation of engine front oil seal ...............................................................................................1952 Removal and installation of engine rear oil seal ................................................................................................1955 Removal and installation of cooling fan and fan motor assembly ..................................................................................1958 Removal and installation of KDPF assembly .......................................................................................................1960 Disassembly and assembly of KDPF assembly .......................................................................................................1963 Removal and installation of KCCV assembly .......................................................................................................1972 Removal and installation of air cleaner assembly ................................................................................................1973 Removal and installation of fuel tank assembly ..................................................................................................1975 Power train .........................................................................................................................................1978 Disassembly and assembly of torque converter assembly ...........................................................................................1978 Disassembly and assembly of transmission assembly ...............................................................................................1985 Disassembly and assembly of transmission clutch pack assembly ...................................................................................1998 Disassembly and assembly of differential assembly ...............................................................................................2012 Disassembly and assembly of parking brake assembly ..............................................................................................2030 Removal and installation of front axle assembly .................................................................................................2038 Removal and installation of rear axle assembly ..................................................................................................2039 Disassembly and assembly of axle housing assembly ...............................................................................................2042 Steering system .....................................................................................................................................2051 Removal and installation of steering valve assembly .............................................................................................2051 Brake system ........................................................................................................................................2053 Removal and installation of parking brake disc and plate ........................................................................................2053 Undercarriage and frame .............................................................................................................................2056 Removal and installation of center hinge pin ....................................................................................................2056 Removal and installation of counterweight assembly ..............................................................................................2064 Removal and installation of full-length fender assembly .........................................................................................2066 Hydraulic system ....................................................................................................................................2067 Removal and installation of hydraulic tank assembly .............................................................................................2067 Removal and installation of work equipment controll valve assembly ..............................................................................2070 Removal and installation of power train pump and work equipment hydraulic pump assembly .........................................................2073 Removal and installation of steering pump and cooling fan pump assembly .........................................................................2074 Disassembly and assembly of hydraulic cylinder assembly .........................................................................................2076 Work equipment ......................................................................................................................................2083 Removal and installation of work equipment assembly .............................................................................................2083 Cab and its attachments .............................................................................................................................2088 Removal and installation of operator's cab and floor frame assembly .............................................................................2088 Removal and installation of operator's cab glass (stuck window glass) ...........................................................................2092 Removal and installation of operator's seat assembly ............................................................................................2100 Removal and installation of seat belt ...........................................................................................................2102 Electrical system ...................................................................................................................................2103 Removal and installation of machine monitor assembly ............................................................................................2103 Removal and installation of engine controller assembly ..........................................................................................2104 Removal and installation of work equipment controller assembly ..................................................................................2105 Removal and installation of transmission controller assembly ....................................................................................2107 Removal and installation of monitor controller assembly .........................................................................................2108 Removal and installation of mass air flow and temperature sensor ................................................................................2110 Removal and installation of KOMTRAX terminal assembly ...........................................................................................2111 60 Maintenance standard .................................................................................................................................2113 Table of contents ...................................................................................................................................2114 Engine and cooling system ...........................................................................................................................2115 Engine related parts ............................................................................................................................2115 Cooling fan pump ................................................................................................................................2116 Cooling fan motor ...............................................................................................................................2119 Power train .........................................................................................................................................2121 Drive shaft .....................................................................................................................................2121 Torque converter ................................................................................................................................2122 Transmission ....................................................................................................................................2124 Transmission control valve ......................................................................................................................2131 Forward and reverse clutch ECMV and gear speed clutch ECMV ......................................................................................2132 Lockup clutch ECMV ..............................................................................................................................2133 Main relief and torque converter relief valve ...................................................................................................2134 Differential ....................................................................................................................................2135 Limited slip differential .......................................................................................................................2138 Final drive .....................................................................................................................................2142 Steering system .....................................................................................................................................2144 Steering column .................................................................................................................................2144 Steering pump ...................................................................................................................................2145 Steering valve ..................................................................................................................................2149 Steering cylinder ...............................................................................................................................2151 Emergency steering pump .........................................................................................................................2153 Brake system ........................................................................................................................................2154 Charge valve ....................................................................................................................................2154 Brake ...........................................................................................................................................2156 Parking brake ...................................................................................................................................2158 Parking brake solenoid valve ....................................................................................................................2159 Undercarriage and frame .............................................................................................................................2160 Axle mount and center hinge pin .................................................................................................................2160 Hydraulic system ....................................................................................................................................2164 Hydraulic tank ..................................................................................................................................2164 Double type gear pump ...........................................................................................................................2165 Work equipment pump .............................................................................................................................2166 Control valve ...................................................................................................................................2171 Stabilizer valve ................................................................................................................................2182 Work equipment ......................................................................................................................................2183 Work equipment linkage ..........................................................................................................................2183 Bucket ..........................................................................................................................................2186 Work equipment cylinder .........................................................................................................................2187 80 Appendix .............................................................................................................................................2189 Table of contents ...................................................................................................................................2190 Air conditioner components ..........................................................................................................................2191 Precautions for refrigerant .....................................................................................................................2191 Air conditioner component .......................................................................................................................2192 Configuration and function of refrigeration cycle ...............................................................................................2194 Outline of refrigeration cycle ..................................................................................................................2195 Air conditioner unit ............................................................................................................................2197 Dual pressure switch ............................................................................................................................2202 Air conditioner controller ......................................................................................................................2203 Compressor ......................................................................................................................................2204 Condenser .......................................................................................................................................2205 Receiver drier ..................................................................................................................................2206 Sunlight sensor .................................................................................................................................2208 Outer temperature sensor (outside air temperature sensor) .......................................................................................2209 Procedure for testing and troubleshooting .......................................................................................................2210 Circuit diagram and arrangement of connector pins ...............................................................................................2212 System diagram ..................................................................................................................................2214 Parts and connectors layout .....................................................................................................................2216 Testing with self-diagnosis function ............................................................................................................2221 Testing temperature control system ..............................................................................................................2224 Testing vent (mode) changeover ..................................................................................................................2226 Testing FRESH/RECIRC air changeover .............................................................................................................2228 Check evaporator temperature sensor .............................................................................................................2230 Testing relays ..................................................................................................................................2232 Troubleshooting chart 1 .........................................................................................................................2234 Troubleshooting chart 2 .........................................................................................................................2235 Information in troubleshooting table ............................................................................................................2237 Failure code list related to air conditioner ....................................................................................................2238 Failure code [879AKA] A/C Inner Sensor Open Circuit .............................................................................................2239 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................2241 Failure code [879BKA] A/C Outer Sensor Open Circuit .............................................................................................2243 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................2245 Failure code [879CKA] Ventilating Sensor Open Circuit ...........................................................................................2247 Failure code [879CKB] Ventilating Sensor Short Circuit ..........................................................................................2249 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .....................................................................................2251 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................2253 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................2256 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ............................................2259 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................................................2262 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..........................................................2265 A-4 Troubleshooting for FRESH/RECIRC air changeover .............................................................................................2268 Troubleshooting with gauge pressure .............................................................................................................2270 Connection of service tool ......................................................................................................................2273 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit .........................................................2275 Handling of compressor oil ......................................................................................................................2277 90 Diagrams and drawings ................................................................................................................................2279 Table of contents ...................................................................................................................................2280 Hydraulic circuit diagram ...........................................................................................................................2281 Symbols in hydraulic circuit diagram ............................................................................................................2281 Power train hydraulic circuit diagram ...........................................................................................................2285 Hydraulic circuit diagram........................................................................................................................2287 Electric circuit diagram ............................................................................................................................2288 Symbols in electric circuit diagram .............................................................................................................2288 Electric circuit diagram of machine body.........................................................................................................2292 Electric circuit diagram of floor................................................................................................................2298 INDEX....................................................................................................................................................2314
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