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KOMATSU WA380-7 WHEEL LOADER SHOP MANUAL VENBM40500 – PDF DOWNLOAD
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Description
KOMATSU WA380-7 WHEEL LOADER SHOP MANUAL VENBM40500 – PDF DOWNLOAD
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KOMATSU WA380-7 WHEEL LOADER SHOP MANUAL VENBM40500 – PDF DOWNLOAD
Language : English
Pages : 2344
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA380-7 WHEEL LOADER SHOP MANUAL VENBM40500 – PDF DOWNLOAD
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 Central lubrication system (CLS)..................................................................................................................... 471 Changing the lubrication interval times.......................................................................................................... 472 Operating the central lubrication system......................................................................................................... 472 Display and control unit......................................................................................................................... 474 LED-display...................................................................................................................................... 474 Push buttons..................................................................................................................................... 474 Three-digit LED display.......................................................................................................................... 475 Check central lubrication system, fill up grease................................................................................................. 476 20 Standard value tables ................................................................................................................................ 479 Table of contents ................................................................................................................................... 480 Standard service value table ........................................................................................................................ 481 Standard value table for engine ................................................................................................................. 481 Standard value table for machine ................................................................................................................ 483 30 Testing and adjusting ................................................................................................................................ 497 Table of contents ................................................................................................................................... 498 General information on testing and adjusting ........................................................................................................ 500 Tools for testing and adjusting ................................................................................................................. 500 Sketch of tools for testing and adjusting ....................................................................................................... 505 Engine and cooling system ........................................................................................................................... 506 Testing engine speed ............................................................................................................................ 506 Measuring boost pressure ........................................................................................................................ 507 Testing exhaust gas temperature ................................................................................................................. 509 Testing exhaust gas color ....................................................................................................................... 511 Testing and adjusting valve clearance ........................................................................................................... 513 Measuring compression pressure .................................................................................................................. 515 Testing blowby pressure ......................................................................................................................... 519 Testing engine oil pressure ..................................................................................................................... 521 Testing EGR valve and KVGT driving oil pressure ................................................................................................. 522 Testing fuel pressure ........................................................................................................................... 523 Testing fuel delivery, return and leakage ....................................................................................................... 528 Bleeding air from fuel system ................................................................................................................... 534 Testing fuel circuit for leakage ................................................................................................................ 536 Handling cylinder cutout mode operation ......................................................................................................... 537 Handling no injection cranking operation ........................................................................................................ 538 Testing of KDPF and muffler stack for looseness and damage ...................................................................................... 539 Testing of installed condition of cylinder head and manifolds ................................................................................... 540 Testing engine piping for damage and looseness .................................................................................................. 541 Testing and adjusting air conditioner compressor belt tension ................................................................................... 542 Replacing alternator belt ....................................................................................................................... 543 Power train ......................................................................................................................................... 544 Adjusting transmission output speed sensor ...................................................................................................... 544 Adjusting transmission input speed sensor ....................................................................................................... 545 Flushing procedure for torque converter and transmission hydraulic circuit ...................................................................... 546 Retrieval of disabled machine due to transmission valve failure ................................................................................. 547 Checking oil leakage from axle final drive ...................................................................................................... 549 Testing drive shaft for looseness, backlash, and damage ......................................................................................... 550 Testing and adjusting power train oil pressure .................................................................................................. 551 Steering system ..................................................................................................................................... 566 Testing directional lever ....................................................................................................................... 566 Testing steering wheel .......................................................................................................................... 567 Testing work equipment control lever ............................................................................................................ 569 Testing and adjusting steering circuit pressure ................................................................................................. 571 Bleeding air from steering cylinder circuit. .................................................................................................... 574 Testing and adjusting steering stopper valve .................................................................................................... 575 Brake system ........................................................................................................................................ 576 Testing brake pedal ............................................................................................................................. 576 Testing and adjusting brake pedal linkage ....................................................................................................... 577 Testing braking performance ..................................................................................................................... 578 Measuring accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas ................................................. 579 Testing and adjusting of accumulator charge pressure ............................................................................................ 583 Testing wheel brake oil pressure ................................................................................................................ 585 Testing lowering of wheel brake pressure ........................................................................................................ 586 Measuring wear of wheel brake disc .............................................................................................................. 589 Bleeding air from wheel brake circuit ........................................................................................................... 590 Releasing remaining pressure in brake accumulator circuit ....................................................................................... 591 Testing parking brake performance ............................................................................................................... 592 Testing parking brake oil pressure .............................................................................................................. 593 Testing wear of parking brake disc .............................................................................................................. 595 Method of releasing parking brake manually ...................................................................................................... 596 Hydraulic system .................................................................................................................................... 597 Checking fan speed .............................................................................................................................. 597 Measuring fan pump circuit oil pressure ......................................................................................................... 598 Bleeding air from hydraulic fan circuit ......................................................................................................... 599 Testing and adjusting work equipment PPC oil pressure ........................................................................................... 600 Testing and adjusting work equipment oil pressure ............................................................................................... 603 Bleeding air from work equipment circuit ........................................................................................................ 607 Releasing remaining pressure from work equipment circuit ........................................................................................ 608 Checking of E.C.S.S. accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ................................. 609 Work equipment ...................................................................................................................................... 613 Testing and adjusting bucket position detection lever ........................................................................................... 613 Testing and adjusting boom position detection lever ............................................................................................. 614 Electrical system ................................................................................................................................... 615 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor .......................................................... 615 Special functions of machine monitor ............................................................................................................ 617 Angle adjustment of rear view camera ............................................................................................................ 711 Handling voltage circuit of engine controller ................................................................................................... 712 Handling battery disconnect switch .............................................................................................................. 713 Testing diodes .................................................................................................................................. 714 Pm clinic ........................................................................................................................................... 715 Pm Clinic service ............................................................................................................................... 715 Check sheet ..................................................................................................................................... 716 40 Troubleshooting ...................................................................................................................................... 721 Table of contents ................................................................................................................................... 722 General information on troubleshooting .............................................................................................................. 732 Troubleshooting points .......................................................................................................................... 732 Sequence of events in troubleshooting ........................................................................................................... 734 Check before troubleshooting .................................................................................................................... 736 Inspection procedure before troubleshooting ..................................................................................................... 738 Preparation work for troubleshooting of electrical system ....................................................................................... 755 Classification and procedures for troubleshooting ............................................................................................... 761 Symptom and troubleshooting numbers ............................................................................................................. 764 Information in troubleshooting table ............................................................................................................ 767 Connector list and layout ....................................................................................................................... 769 T-branch box and T-branch adapter table ......................................................................................................... 785 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ......................................................... 791 Fuse location table ............................................................................................................................. 794 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................................................................... 797 Precautions on troubleshooting of machine monitor ............................................................................................... 800 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ......................................................... 802 Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................................. 807 Fabrication of short-circuit connector (for CA1883 and CA3135) .................................................................................. 808 Failure codes table ............................................................................................................................. 809 Troubleshooting by failure code (Display of code) ................................................................................................... 823 Failure code [1500L0] Double Engagement of T/M Clutches ......................................................................................... 823 Failure code [15SAL1] Release Trouble of ECMV (Forward) ......................................................................................... 824 Failure code [15SALH] Malfunction of ECMV (Forward) ............................................................................................. 826 Failure code [15SBL1] Release Trouble of ECMV (Reverse) ......................................................................................... 828 Failure code [15SBLH] Malfunction of ECMV (Reverse) ............................................................................................. 830 Failure code [15SEL1] Release Trouble of ECMV (1st) ............................................................................................. 832 Failure code [15SELH] Malfunction of ECMV (1st) ................................................................................................. 834 Failure code [15SFL1] Release Trouble of ECMV (2nd) ............................................................................................. 836 Failure code [15SFLH] Malfunction of ECMV (2nd) ................................................................................................. 838 Failure code [15SGL1] Release Trouble of ECMV (3rd) ............................................................................................. 840 Failure code [15SGLH] Malfunction of ECMV (3rd) ................................................................................................. 842 Failure code [15SHL1] Release Trouble of ECMV (4th) ............................................................................................. 844 Failure code [15SHLH] Malfunction of ECMV (4th) ................................................................................................. 846 Failure code [2F00MA] Failure of Parking Brake Circuit .......................................................................................... 848 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...................................................................................... 851 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....................................................................................... 853 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................................. 855 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................ 856 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................................. 857 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................ 858 Failure code [879CKA] Ventilating Sensor Open Circuit ........................................................................................... 859 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................................................... 860 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..................................................................................... 861 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................ 862 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................ 863 Failure code [989A00] Engine Overrun Prevention Activated ....................................................................................... 864 Failure code [989L00] Engine Controller Lock Caution 1 .......................................................................................... 865 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................................... 866 Failure code [989N00] Engine Controller Lock Caution 3 .......................................................................................... 867 Failure code [A1U0N3] HC Desorb Request 1 ....................................................................................................... 868 Failure code [A1U0N4] HC Desorb Request 2 ....................................................................................................... 870 Failure code [AA10NX] Air Cleaner Clogging ...................................................................................................... 872 Failure code [B@BAZG] Eng Oil Press Low ......................................................................................................... 874 Failure code [B@BAZK] Engine Oil Level Low ...................................................................................................... 875 Failure code [B@BCNS] Eng Water Overheat ........................................................................................................ 876 Failure code [B@BCZK] Eng Water Level Low ....................................................................................................... 877 Failure code [B@CENS] T/C Oil Temp. Overheat .................................................................................................... 879 Failure code [B@HANS] HYD Oil Temp. Overheat .................................................................................................... 880 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................................... 881 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................................ 882 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................................. 884 Failure code [CA131] Throttle Sensor High Error ................................................................................................. 886 Failure code [CA132] Throttle Sensor Low Error .................................................................................................. 888 Failure code [CA144] Coolant Temp Sens High Error ............................................................................................... 890 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................................ 892 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................................. 894 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................................. 896 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................................. 898 Failure code [CA221] Ambient Press Sens High Error .............................................................................................. 900 Failure code [CA222] Ambient Press Sens Low Error ............................................................................................... 902 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................................ 904 Failure code [CA234] Eng Overspeed .............................................................................................................. 905 Failure code [CA238] Ne Speed Sensor Supply Volt Error .......................................................................................... 906 Failure code [CA239] Ne Speed Sens Supply Volt High Error ....................................................................................... 907 Failure code [CA271] IMV/PCV1 Short Error ....................................................................................................... 908 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................................ 910 Failure code [CA295] Ambient Press Sens In Range Error .......................................................................................... 912 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................................................... 913 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................................................... 915 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................................................... 917 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................................................... 919 Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................................................... 921 Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................................................... 923 Failure code [CA343] ECM Critical Internal Failure .............................................................................................. 925 Failure code [CA351] Injectors Drive Circuit Error .............................................................................................. 926 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................................. 927 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................................ 929 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................................. 931 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................................ 933 Failure code [CA428] Water in Fuel Sensor High Error ............................................................................................ 934 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................................. 936 Failure code [CA431] Idle Validation Sw Error ................................................................................................... 938 Failure code [CA432] Idle Validation Process Error .............................................................................................. 941 Failure code [CA435] Eng Oil Press Sw Error ..................................................................................................... 944 Failure code [CA441] Battery Voltage Low Error .................................................................................................. 945 Failure code [CA442] Battery Voltage High Error ................................................................................................. 947 Failure code [CA449] Rail Press Very High Error ................................................................................................. 948 Failure code [CA451] Rail Press Sensor High Error ............................................................................................... 949 Failure code [CA452] Rail Press Sensor Low Error ................................................................................................ 951 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................................ 953 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................................ 954 Failure code [CA516] Rail Press Sens Sup Volt Low Error ......................................................................................... 956 Failure code [CA553] Rail Press High Error ...................................................................................................... 958 Failure code [CA555] Crankcase Press High Error 1 ............................................................................................... 959 Failure code [CA556] Crankcase Press High Error 2 ............................................................................................... 960 Failure code [CA559] Rail Press Low Error ....................................................................................................... 961 Failure code [CA595] Turbo Speed High Error 2 ................................................................................................... 963 Failure code [CA687] Turbo Speed Low Error ...................................................................................................... 964 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................................. 966 Failure code [CA691] Intake Air Temp Sens High Error ............................................................................................ 968 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................................. 970 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................................ 972 Failure code [CA698] ECM Int Temp Sensor Low Error .............................................................................................. 973 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................................ 974 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................................ 976 Failure code [CA1117] Persistent Data Lost Error ................................................................................................ 981 Failure code [CA1664] KDOC Malfunction .......................................................................................................... 982 Failure code [CA1691] Regeneration Ineffective .................................................................................................. 985 Failure code [CA1695] Sensor 5 Supply Volt High Error ........................................................................................... 988 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................................................ 989 Failure code [CA1843] Crankcase Press Sens High Error ........................................................................................... 991 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................................................ 993 Failure code [CA1879] KDPF Delta P Sensor High Error ............................................................................................ 995 Failure code [CA1881] KDPF Delta P Sensor Low Error ............................................................................................. 997 Failure code [CA1883] KDPF Delta P Sens In Range Error .......................................................................................... 999 Failure code [CA1921] KDPF Soot Load High Error 1 ...............................................................................................1004 Failure code [CA1922] KDPF Soot Load High Error 2 ...............................................................................................1007 Failure code [CA1942] Crankcase Press Sens In Range Error .......................................................................................1011 Failure code [CA1993] KDPF Delta Pressure Low Error .............................................................................................1012 Failure code [CA2185] Throt Sensor Sup Volt High Error ..........................................................................................1015 Failure code [CA2186] Throt Sensor Sup Volt Low Error ...........................................................................................1017 Failure code [CA2249] Rail Press Very Low Error .................................................................................................1019 Failure code [CA2271] EGR Valve Pos Sens High Error .............................................................................................1020 Failure code [CA2272] EGR Valve Pos Sens Low Error ..............................................................................................1022 Failure code [CA2288] Turbo Speed High Error 1 ..................................................................................................1025 Failure code [CA2311] IMV Solenoid Error ........................................................................................................1026 Failure code [CA2349] EGR Valve Solenoid Open Error .............................................................................................1027 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................................1029 Failure code [CA2357] EGR Valve Servo Error .....................................................................................................1031 Failure code [CA2373] Exhaust Manifold Press Sens High error ....................................................................................1032 Failure code [CA2374] Exhaust Manifold Press Sens Low error .....................................................................................1034 Failure code [CA2375] EGR Orifice Temp Sens High Error ..........................................................................................1036 Failure code [CA2376] EGR Orifice Temp Sens Low Error ...........................................................................................1038 Failure code [CA2381] KVGT Pos Sens High Error ..................................................................................................1040 Failure code [CA2382] KVGT Pos Sens Low Error ...................................................................................................1042 Failure code [CA2383] KVGT Solenoid Open Error ..................................................................................................1045 Failure code [CA2386] KVGT Solenoid Short Error .................................................................................................1047 Failure code [CA2387] KVGT Servo Error ..........................................................................................................1049 Failure code [CA2554] Exh Manifold Press Sens In Range Error ....................................................................................1050 Failure code [CA2555] Grid Htr Relay Volt Low Error .............................................................................................1051 Failure code [CA2556] Grid Htr Relay Volt High Error ............................................................................................1053 Failure code [CA2637] KDOC Face Plugging ........................................................................................................1055 Failure code [CA2639] Manual Stationary Regeneration Request ....................................................................................1057 Failure code [CA2961] EGR Orifice Temp High Error 1 .............................................................................................1060 Failure code [CA2973] Chg Air Press Sensor In Range Error .......................................................................................1061 Failure code [CA3133] KDPF Outlet Press Sens High Error .........................................................................................1062 Failure code [CA3134] KDPF Outlet Press Sens Low Error ..........................................................................................1064 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .....................................................................................1066 Failure code [CA3251] KDOC Inlet Temp High Error ................................................................................................1070 Failure code [CA3253] KDOC Temp Error - Non Regeneration ........................................................................................1073 Failure code [CA3254] KDOC Outlet Temp High Error 1 .............................................................................................1076 Failure code [CA3255] KDPF Temp Error - Non Regeneration ........................................................................................1079 Failure code [CA3256] KDPF Outlet Temp High Error 1 .............................................................................................1082 Failure code [CA3311] KDOC Outlet Temp High Error 2 .............................................................................................1085 Failure code [CA3312] KDPF Outlet Temp High Error 2 .............................................................................................1088 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ..........................................................................................1091 Failure code [CA3314] KDOC Inlet Temp Sens High Error ...........................................................................................1094 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .......................................................................................1098 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...........................................................................................1103 Failure code [CA3317] KDOC Outlet Temp Sens High Error ..........................................................................................1106 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ......................................................................................1110 Failure code [CA3319] KDPF Outlet Temp Sens High Error ..........................................................................................1115 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...........................................................................................1119 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ......................................................................................1122 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ..................................................................................1126 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...................................................................................1128 Failure code [CA3741] Rail Press Valve Trip Error ...............................................................................................1130 Failure code [D150KA] Disconnection of Emerg. Steering Relay ....................................................................................1131 Failure code [D150KB] Ground Fault of Emerg. Steering Relay .....................................................................................1133 Failure code [D150KY] Hot Short of Emergency Steering Relay .....................................................................................1135 Failure code [D160KA] Disconnection of Backup Lamp Relay Output .................................................................................1137 Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ..................................................................................1139 Failure code [D160KY] Hot Short of Backup Lamp Relay Output .....................................................................................1141 Failure code [D191KA] Disconnection of Neutral Output Relay .....................................................................................1143 Failure code [D191KB] Ground Fault of Neutral Output Relay ......................................................................................1146 Failure code [D191KY] Hot Short of Neutral Output Relay .........................................................................................1149 Failure code [D192KA] Disconnection of ECSS Solenoid ............................................................................................1151 Failure code [D192KB] Ground Fault of ECSS Solenoid .............................................................................................1153 Failure code [D192KY] Hot Short of ECSS Solenoid ................................................................................................1154 Failure code [D19JKZ] Personal Code Relay Abnormality ...........................................................................................1155 Failure code [D1E6KA] Disconnection of Parking Brake Relay ......................................................................................1157 Failure code [D1E6KB] Ground Fault of Parking Brake Relay .......................................................................................1159 Failure code [D1E6KY] Hot Short of Parking Brake Relay ..........................................................................................1161 Failure code [D5ZHKA] Failure of Key SW C Signal ................................................................................................1163 Failure code [D5ZHKB] Key SW C Signal Short Circuit .............................................................................................1165 Failure code [D5ZHKZ] Failure of Key SW C Signal ................................................................................................1167 Failure code [D5ZHL6] Disconnection of Key SW C .................................................................................................1169 Failure code [D811MC] KOMTRAX Error .............................................................................................................1171 Failure code [D862KA] GPS Antenna Open Circuit ..................................................................................................1172 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .....................................................................................1173 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ....................................................................................1175 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...................................................................................................1177 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .....................................................................................................1178 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................................................................1179 Failure code [DAF0MB] Monitor ROM Abnormality ...................................................................................................1180 Failure code [DAF0MC] Monitor Error .............................................................................................................1181 Failure code [DAF3KK] Controller Power Source Low (MON) .........................................................................................1182 Failure code [DAF8KB] Camera Power Supply Short Circuit .........................................................................................1184 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ....................................................................................1185 Failure code [DAFGMC] GPS Module Error ..........................................................................................................1187 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) .........................................................................................1188 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ........................................................................................1190 Failure code [DAFQKR] CAN2 Discon (Monitor) .....................................................................................................1192 Failure code [DAQ0KK] Controller Power Source Low (T/M) .........................................................................................1193 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ..................................................................................1196 Failure code [DAQ0MC] T/M Con Error .............................................................................................................1197 Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .........................................................................................1198 Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ...........................................................................................1200 Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ...................................................................................1203 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ....................................................................................1205 Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) .........................................................................................1206 Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ........................................................................................1208 Failure code [DAQQKR] CAN2 Discon (Transmission Con) ............................................................................................1210 Failure code [DAQRKR] CAN1 Discon (Transmission Con) ............................................................................................1211 Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ...................................................................................1212 Failure code [DAZ9KQ] A/C Model Selection Abnormality ...........................................................................................1213 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ..................................................................................................1214 Failure code [DB2QKR] CAN2 Discon (Engine Con) ..................................................................................................1215 Failure code [DB2RKR] CAN1 Discon (Engine Con) ..................................................................................................1220 Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................................................................1226 Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ..................................................................................1228 Failure code [DB90MC] BBC Error .................................................................................................................1229 Failure code [DB91KA] Disconnection of Key SW ACC (BBC) .........................................................................................1230 Failure code [DB92KK] Solenoid Power Source Low (BBC) ...........................................................................................1232 Failure code [DB95KX] Failure of 5 V Power Source 1 .............................................................................................1234 Failure code [DB96KX] Failure of 5 V Power Source 2 .............................................................................................1238 Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ....................................................................................1242 Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) .........................................................................................1243 Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ........................................................................................1245 Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .............................................................................................1247 Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .............................................................................................1248 Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ...................................................................................1249 Failure code [DBE5KX] Failure of 5 V Power Source ...............................................................................................1250 Failure code [DBE6KX] Failure of 24 V Power Source ..............................................................................................1252 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................................................................1254 Failure code [DDAAL6] Discon Engine Shutdown Secondary Switch ...................................................................................1258 Failure code [DDB6L4] Neutral Signal Malfunction ................................................................................................1260 Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ...................................................................................1263 Failure code [DDK3KA] FNR SW Input Signal Disconnection .........................................................................................1267 Failure code [DDK3KB] FNR SW Input Signal Short Circuit .........................................................................................1272 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ......................................................................................1276 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ......................................................................................1279 Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................................................................1281 Failure code [DDT0L4] Failure of Shift Mode Select SW ...........................................................................................1285 Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal .................................................................................1289 Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal .....................................................................................1293 Failure code [DDW9LD] Ground Fault of Kickdown Switch ...........................................................................................1297 Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW .........................................................................................1301 Failure code [DF10KA] Disconnection of Shift Lever Input ........................................................................................1305 Failure code [DF10KB] Ground Fault of Shift Lever Input .........................................................................................1307 Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor .....................................................................................1310 Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ......................................................................................1312 Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ......................................................................................1314 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ....................................................................................1316 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .........................................................................................1317 Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor .....................................................................................1319 Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ......................................................................................1321 Failure code [DH21KA] Failure of Loader Pump Press. Sensor ......................................................................................1323 Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ...................................................................................1325 Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit .....................................................................................1327 Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor .................................................................................1329 Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ...................................................................................1331 Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor .................................................................................1333 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .................................................................................1335 Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ................................................................................1338 Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ....................................................................................1340 Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit .................................................................................1342 Failure code [DHT8ZG] Steering Oil Pressure Low .................................................................................................1344 Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ...................................................................................1345 Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ....................................................................................1347 Failure code [DJF1KA] Disconnection of Fuel Level Sensor ........................................................................................1349 Failure code [DK55KA] Failure of FNR Lever Potentio .............................................................................................1351 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...................................................................................1354 Failure code [DK55L5] Failure of FNR Lever Potentio .............................................................................................1356 Failure code [DK59KA] Failure of Boom Lever Potentio (Main) .....................................................................................1357 Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ...................................................................................1363 Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................................................................1368 Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ......................................................................................1375 Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ....................................................................................1381 Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ...................................................................................1386 Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) .................................................................................1391 Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................................................................1396 Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ....................................................................................1403 Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ..................................................................................1408 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ......................................................................................1413 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ....................................................................................1418 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ..................................................................................1422 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) .......................................................................................1428 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) .....................................................................................1433 Failure code [DK5KKA] Failure of 4th Lever Potentio (Main) ......................................................................................1437 Failure code [DK5KKY] Hot Short of 4th Lever Potentio (Main) ....................................................................................1442 Failure code [DK5KL8] 4th Lever Potentio (Main & Sub) Disagree ..................................................................................1446 Failure code [DK5LKA] Failure of 4th Lever Potentio (Sub) .......................................................................................1452 Failure code [DK5LKY] Hot Short of 4th Lever Potentio (Sub) .....................................................................................1457 Failure code [DKA0KA] Failure of Boom Angle Sensor ..............................................................................................1461 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ....................................................................................1463 Failure code [DKA0L0] Boom Angle Sensor Dislocation .............................................................................................1465 Failure code [DKA1KA] Failure of Bucket Angle Sensor ............................................................................................1467 Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ..................................................................................1470 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ...................................................................................1472 Failure code [DLF1LC] Failure of T/M Input Speed Sensor .........................................................................................1474 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ................................................................................1476 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ......................................................................................1478 Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ................................................................................1480 Failure code [DLT3LC] Failure of Output Speed Sensor (Main) .....................................................................................1482 Failure code [DPQ1KR] LIN Discon (Switch Panel) .................................................................................................1484 Failure code [DPQ2KR] LIN Discon (LED Unit) .....................................................................................................1487 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ............................................................................................1490 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ..................................................................................................1493 Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .....................................................................................1494 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...................................................................................1498 Failure code [DV00KB] Ground Fault of Buzzer Output .............................................................................................1502 Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................................................................1504 Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) .................................................................................1506 Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................................................................1508 Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ................................................................................1510 Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) .................................................................................1512 Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ....................................................................................1514 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...................................................................................1516 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ................................................................................1518 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...................................................................................1520 Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ...................................................................................1522 Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................................................................1524 Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ...................................................................................1526 Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid .....................................................................................1528 Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ....................................................................................1529 Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. .......................................................................................1531 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ....................................................................................1532 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid .....................................................................................1534 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ........................................................................................1536 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................................................................1538 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ....................................................................................1542 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) .......................................................................................1546 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) .................................................................................1550 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ..................................................................................1554 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) .....................................................................................1558 Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ...................................................................................1562 Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................................................................1564 Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ...................................................................................1566 Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid .................................................................................1568 Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ..................................................................................1570 Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid .....................................................................................1572 Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...................................................................................1573 Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ................................................................................1575 Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid ...................................................................................1577 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ...................................................................................1578 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................................................................1580 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .......................................................................................1582 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ......................................................................................1584 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) .......................................................................................1586 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ..........................................................................................1588 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ......................................................................................1590 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .......................................................................................1592 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ..........................................................................................1594 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ......................................................................................1596 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) .......................................................................................1597 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ..........................................................................................1599 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ..................................................................................1601 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ...................................................................................1603 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ......................................................................................1605 Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ..................................................................................1607 Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ...................................................................................1608 Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ......................................................................................1610 Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ......................................................................................1612 Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) .......................................................................................1614 Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ..........................................................................................1616 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...................................................................................1618 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ....................................................................................1620 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .......................................................................................1622 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................................................................1624 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ....................................................................................1626 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) .......................................................................................1628 Failure code [DXJEKA] Disconnection of 4th EPC Solenoid (EXT) ...................................................................................1630 Failure code [DXJEKB] Ground Fault of 4th EPC Solenoid (EXT) ....................................................................................1632 Failure code [DXJEKY] Hot Short of 4th EPC Solenoid (EXT) .......................................................................................1634 Failure code [DXJFKA] Disconnection of 4th EPC Solenoid (RET) ...................................................................................1636 Failure code [DXJFKB] Ground Fault of 4th EPC Solenoid (RET) ....................................................................................1638 Failure code [DXJFKY] Hot Short of 4th EPC Solenoid (RET) .......................................................................................1640 Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor ....................................................................................1642 Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor ....................................................................................1645 Failure code [DY30ME] Emerg. Steering Long-Time Activated .......................................................................................1649 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ......................................................................................1651 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ....................................................................................1654 Failure code [LA00L3] Failure of Fan Reverse ....................................................................................................1656 Troubleshooting of electrical system (E-mode) .......................................................................................................1657 E-1 Engine does not start .......................................................................................................................1657 E-2 Manual preheating system does not work ......................................................................................................1664 E-3 Automatic preheating system does not work ...................................................................................................1667 E-4 While preheating is working, preheating monitor does not light up ...........................................................................1669 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ................................................................1671 E-6 LCD unit on machine monitor displays nothing ................................................................................................1674 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) .......................................................1676 E-8 LCD on machine monitor does not display properly ............................................................................................1678 E-9 Meter unit display on machine monitor is abnormal ...........................................................................................1680 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...........................................................................1683 E-11 Caution LED on machine monitor is abnormal .................................................................................................1686 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...................................................1688 E-13 Two switches operation of switch panel on machine monitor does not function ................................................................1690 E-14 Switch panel buzzer of machine monitor is abnormal .........................................................................................1693 E-15 Rear view monitor does not light up or backlight flickers ..................................................................................1695 E-16 Rear view monitor images are not displayed clearly .........................................................................................1698 E-17 Rear view monitor brightness cannot be adjusted ............................................................................................1701 E-18 Night lighting lamp of rear view monitor is abnormal .......................................................................................1704 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly .......................................................1706 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position .........................................1707 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ..............................................1711 E-22 Air cleaner clogging indicator lamp does not light .........................................................................................1713 E-23 Radiator coolant level caution lamp does not light .........................................................................................1714 E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ..................1716 E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ....1718 E-26 Fuel level gauge does not indicate correct level ...........................................................................................1719 E-27 Seat belt caution lamp indication is abnormal ..............................................................................................1721 E-28 Horn does not sound ........................................................................................................................1722 E-29 Horn does not stop sounding ................................................................................................................1725 E-30 Alarm buzzer does not sound ................................................................................................................1727 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................................................................1728 E-32 Kickdown does not work when kickdown switch is turned ON ...................................................................................1729 E-33 The hold switch does not work when it is pressed ...........................................................................................1731 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 ..............1733 E-35 Transmission cut-off mode is not selected or not released ..................................................................................1736 E-36 Transmission cut-off setting cannot be released ............................................................................................1738 E-37 Directional selector (FNR) switch mode is not selected or not released .....................................................................1740 E-38 When operating engine power selection switch, engine power selection function does not operate properly ....................................1742 E-39 Flow of loader pump does not increase from the minimum rate ................................................................................1744 E-40 ECSS function cannot be selected or cannot be released .....................................................................................1745 E-41 None of headlamp, clearance lamp, and tail lamp lights .....................................................................................1747 E-42 Clearance lamp and tail lamp do not light up or go out .....................................................................................1749 E-43 Both "High and Low beams" of headlamp do not light up or go out ............................................................................1752 E-44 The headlamp "Low beam" does not light up or go out ........................................................................................1756 E-45 The headlamp "High beam" does not light up or go out .......................................................................................1758 E-46 Front working lamp does not light up or go out .............................................................................................1760 E-47 Rear working lamp does not light up or go out ..............................................................................................1763 E-48 All of turn signal lamps and hazard lamps do not light up or go out ........................................................................1766 E-49 Turn signal lamps do not light up or go out ................................................................................................1769 E-50 Hazard lamp does not light up or go out ....................................................................................................1772 E-51 Brake lamp does not light up or stays lighted ..............................................................................................1775 E-52 Backup lamp does not light or continues to light ...........................................................................................1778 E-53 Backup buzzer does not sound or continues to sound .........................................................................................1781 E-54 Front wiper does not operate ...............................................................................................................1783 E-55 Rear wiper does not operate ................................................................................................................1786 E-56 Window washer does not operate .............................................................................................................1788 E-57 KOMTRAX system does not operate properly ...................................................................................................1791 Troubleshooting of hydraulic and mechanical system (H-mode) .........................................................................................1793 Information described in troubleshooting table (H-mode) .........................................................................................1793 System chart of hydraulic and mechanical systems ................................................................................................1794 Failure mode and cause table ....................................................................................................................1796 H-1 Machine does not start ......................................................................................................................1802 H-2 Torque converter lockup clutch is not disengaged (engine stalls) ............................................................................1805 H-3 Torque converter lockup clutch is not engaged ...............................................................................................1806 H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift .........................................1807 H-5 Large shock is made when machine starts or gear is shifted ..................................................................................1810 H-6 Machine starts or gear speed shifts with long time lag ......................................................................................1813 H-7 Torque converter oil temperature is high ....................................................................................................1815 H-8 Machine does not turn .......................................................................................................................1818 H-9 Turning response is poor ....................................................................................................................1820 H-10 Steering wheel is heavy to turn ............................................................................................................1822 H-11 Machine sways or large shocks are made while machine turns .................................................................................1823 H-12 Turning radius differs between right and left turns ........................................................................................1825 H-13 Wheel brakes do not work or are weak .......................................................................................................1826 H-14 Wheel brakes are not released or drag ......................................................................................................1827 H-15 Parking brake does not work or it is weak ..................................................................................................1828 H-16 Parking brake is not released or drags (including emergency release system) ................................................................1829 H-17 Boom does not rise .........................................................................................................................1830 H-18 Boom moves slow or boom lacks lifting force ................................................................................................1832 H-19 Rising boom slows down at certain height ...................................................................................................1834 H-20 Lift cylinders do not serve to hold bucket on ground .......................................................................................1835 H-21 Hydraulic drift of boom is large ...........................................................................................................1836 H-22 Boom moves up and down during operation ....................................................................................................1837 H-23 Bucket does not tilt back ..................................................................................................................1838 H-24 Bucket moves slow or bucket lacks tilt-back force ..........................................................................................1840 H-25 Bucket decelerates during tilt-back operation ..............................................................................................1842 H-26 Bucket cylinder does not hold bucket on ground .............................................................................................1843 H-27 Hydraulic drift of bucket is large .........................................................................................................1844 H-28 Bucket tilts back and forth during carrying load (work equipment valve in "HOLD") ..........................................................1845 H-29 Boom and bucket control levers do not move smoothly and heavy to move ......................................................................1846 H-30 Operating work equipment causes engine speed to lower significantly or engine to stall .....................................................1848 H-31 Large shocks are made when work equipment starts to move and stops .........................................................................1849 H-32 When certain work equipment stalls hydraulically, other work equipment moves ...............................................................1851 H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces .....................................................................1852 H-34 Air conditioner does not work while cooling fan rotates in reverse mode ....................................................................1853 H-35 Fan speed is abnormal (too high or low, or fan doe not rotate) .............................................................................1854 H-36 Unusual noise is heard from around fan .....................................................................................................1855 Troubleshooting of engine (S-mode) ..................................................................................................................1856 Information described in troubleshooting table (S mode) .........................................................................................1856 S-1 Engine does not crank when starting switch is turned to "START" position ....................................................................1857 S-2 Engine cranks but no exhaust smoke comes out ................................................................................................1858 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ..............................................1859 S-4 Engine startability is poor .................................................................................................................1860 S-5 Engine does not pick up smoothly ............................................................................................................1862 S-6 Engine stops during operation ...............................................................................................................1864 S-7 Engine runs rough or is unstable ............................................................................................................1866 S-8 Engine lacks power ..........................................................................................................................1867 S-9 Exhaust smoke is black (KDPF gets clogged in a short time) ..................................................................................1869 S-10 Engine oil consumption is excessive ........................................................................................................1871 S-11 Engine oil becomes contaminated early ......................................................................................................1872 S-12 Fuel consumption is excessive ..............................................................................................................1873 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...........................................................................1874 S-14 Oil pressure drops .........................................................................................................................1875 S-15 Fuel mixes into engine oil .................................................................................................................1876 S-16 Water mixes into engine oil (milky) ........................................................................................................1877 S-17 Coolant temperature rises too high (overheating) ...........................................................................................1878 S-18 Unusual noise is heard .....................................................................................................................1879 S-19 Vibration is excessive .....................................................................................................................1880 S-20 Air cannot be bled from fuel circuit .......................................................................................................1881 S-21 Active regeneration is executed frequently .................................................................................................1882 S-22 Active regeneration takes time .............................................................................................................1883 S-23 White smoke is exhausted during active regeneration ........................................................................................1884 Troubleshooting of Central Lubrication System (CLS)..................................................................................................1885 Trouble..........................................................................................................................................1885 Troubleshooting FPS..............................................................................................................................1886 Troubleshooting..................................................................................................................................1887 Pump Faults......................................................................................................................................1888 Replace pump element.............................................................................................................................1889 Check power supply...............................................................................................................................1889 Changing the control unit .......................................................................................................................1889 Troubleshooting – grease system faults...........................................................................................................1890 General assembly advice..........................................................................................................................1892 50 Disassembly and assembly .............................................................................................................................1893 Table of contents ...................................................................................................................................1894 General information on disassembly and assembly .....................................................................................................1896 How to read this manual .........................................................................................................................1896 Coating materials list ..........................................................................................................................1898 Special tools list ..............................................................................................................................1902 Sketches of special tools .......................................................................................................................1905 Engine and cooling system ...........................................................................................................................1912 Removal and installation of supply pump assembly ................................................................................................1912 Removal and installation of injector assembly ...................................................................................................1915 Removal and installation of cylinder head assembly ..............................................................................................1926 Removal and installation of engine hood assembly ................................................................................................1945 Removal and installation of grille assembly .....................................................................................................1948 Removal and installation of cooling system assembly .............................................................................................1949 Removal and installation of radiator core assembly ..............................................................................................1952 Removal and installation of aftercooler .........................................................................................................1955 Removal and installation of hydraulic oil cooler assembly .......................................................................................1957 Removal and installation of fuel cooler assembly ................................................................................................1958 Removal and installation of engine, torque converter and transmission assemblies ................................................................1959 Disconnection and connection of engine, torque converter and transmission assembly ..............................................................1966 Removal and installation of engine front oil seal ...............................................................................................1968 Removal and installation of engine rear oil seal ................................................................................................1971 Removal and installation of cooling fan and fan motor assembly ..................................................................................1974 Removal and installation of KDPF assembly .......................................................................................................1976 Disassembly and assembly of KDPF assembly .......................................................................................................1979 Removal and installation of KCCV assembly .......................................................................................................1988 Removal and installation of air cleaner assembly ................................................................................................1989 Removal and installation of fuel tank assembly ..................................................................................................1991 Power train .........................................................................................................................................1994 Disassembly and assembly of torque converter assembly ...........................................................................................1994 Disassembly and assembly of transmission assembly ...............................................................................................2001 Disassembly and assembly of transmission clutch pack assembly ...................................................................................2014 Disassembly and assembly of differential assembly ...............................................................................................2028 Disassembly and assembly of parking brake assembly ..............................................................................................2046 Removal and installation of front axle assembly .................................................................................................2054 Removal and installation of rear axle assembly ..................................................................................................2055 Disassembly and assembly of axle housing assembly ...............................................................................................2058 Steering system .....................................................................................................................................2067 Removal and installation of steering valve assembly .............................................................................................2067 Brake system ........................................................................................................................................2069 Removal and installation of parking brake disc and plate ........................................................................................2069 Undercarriage and frame .............................................................................................................................2072 Removal and installation of center hinge pin ....................................................................................................2072 Removal and installation of counterweight assembly ..............................................................................................2080 Removal and installation of full-length fender assembly .........................................................................................2082 Hydraulic system ....................................................................................................................................2083 Removal and installation of hydraulic tank assembly .............................................................................................2083 Removal and installation of work equipment controll valve assembly ..............................................................................2086 Removal and installation of power train pump and work equipment hydraulic pump assembly .........................................................2089 Removal and installation of steering pump and cooling fan pump assembly .........................................................................2090 Disassembly and assembly of hydraulic cylinder assembly .........................................................................................2092 Work equipment ......................................................................................................................................2099 Removal and installation of work equipment assembly .............................................................................................2099 Cab and its attachments .............................................................................................................................2104 Removal and installation of operator's cab and floor frame assembly .............................................................................2104 Removal and installation of operator's cab glass (stuck window glass) ...........................................................................2108 Removal and installation of operator's seat assembly ............................................................................................2116 Removal and installation of seat belt ...........................................................................................................2118 Electrical system ...................................................................................................................................2119 Removal and installation of machine monitor assembly ............................................................................................2119 Removal and installation of engine controller assembly ..........................................................................................2120 Removal and installation of work equipment controller assembly ..................................................................................2121 Removal and installation of transmission controller assembly ....................................................................................2123 Removal and installation of monitor controller assembly .........................................................................................2124 Removal and installation of mass air flow and temperature sensor ................................................................................2126 Removal and installation of KOMTRAX terminal assembly ...........................................................................................2127 60 Maintenance standard .................................................................................................................................2129 Table of contents ...................................................................................................................................2130 Engine and cooling system ...........................................................................................................................2131 Engine related parts ............................................................................................................................2131 Cooling fan pump ................................................................................................................................2132 Cooling fan motor ...............................................................................................................................2135 Power train .........................................................................................................................................2137 Drive shaft .....................................................................................................................................2137 Torque converter ................................................................................................................................2138 Transmission ....................................................................................................................................2140 Transmission control valve ......................................................................................................................2147 Forward and reverse clutch ECMV and gear speed clutch ECMV ......................................................................................2148 Lockup clutch ECMV ..............................................................................................................................2149 Main relief and torque converter relief valve ...................................................................................................2150 Differential ....................................................................................................................................2151 Limited slip differential .......................................................................................................................2154 Final drive .....................................................................................................................................2158 Steering system .....................................................................................................................................2160 Steering column .................................................................................................................................2160 Steering pump ...................................................................................................................................2161 Steering valve ..................................................................................................................................2165 Steering cylinder ...............................................................................................................................2167 Emergency steering pump .........................................................................................................................2169 Brake system ........................................................................................................................................2170 Charge valve ....................................................................................................................................2170 Brake ...........................................................................................................................................2172 Parking brake ...................................................................................................................................2174 Parking brake solenoid valve ....................................................................................................................2175 Undercarriage and frame .............................................................................................................................2176 Axle mount and center hinge pin .................................................................................................................2176 Hydraulic system ....................................................................................................................................2180 Hydraulic tank ..................................................................................................................................2180 Double type gear pump ...........................................................................................................................2181 Work equipment pump .............................................................................................................................2182 Control valve ...................................................................................................................................2187 Stabilizer valve ................................................................................................................................2198 Work equipment ......................................................................................................................................2199 Work equipment linkage ..........................................................................................................................2199 Bucket ..........................................................................................................................................2202 Work equipment cylinder .........................................................................................................................2203 80 Appendix .............................................................................................................................................2205 Table of contents ...................................................................................................................................2206 Air conditioner components ..........................................................................................................................2207 Precautions for refrigerant .....................................................................................................................2207 Air conditioner component .......................................................................................................................2208 Configuration and function of refrigeration cycle ...............................................................................................2210 Outline of refrigeration cycle ..................................................................................................................2211 Air conditioner unit ............................................................................................................................2213 Dual pressure switch ............................................................................................................................2218 Air conditioner controller ......................................................................................................................2219 Compressor ......................................................................................................................................2220 Condenser .......................................................................................................................................2221 Receiver drier ..................................................................................................................................2222 Sunlight sensor .................................................................................................................................2224 Outer temperature sensor (outside air temperature sensor) .......................................................................................2225 Procedure for testing and troubleshooting .......................................................................................................2226 Circuit diagram and arrangement of connector pins ...............................................................................................2228 System diagram ..................................................................................................................................2230 Parts and connectors layout .....................................................................................................................2232 Testing with self-diagnosis function ............................................................................................................2237 Testing temperature control system ..............................................................................................................2240 Testing vent (mode) changeover ..................................................................................................................2242 Testing FRESH/RECIRC air changeover .............................................................................................................2244 Check evaporator temperature sensor .............................................................................................................2246 Testing relays ..................................................................................................................................2248 Troubleshooting chart 1 .........................................................................................................................2250 Troubleshooting chart 2 .........................................................................................................................2251 Information in troubleshooting table ............................................................................................................2253 Failure code list related to air conditioner ....................................................................................................2254 Failure code [879AKA] A/C Inner Sensor Open Circuit .............................................................................................2255 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................2257 Failure code [879BKA] A/C Outer Sensor Open Circuit .............................................................................................2259 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................2261 Failure code [879CKA] Ventilating Sensor Open Circuit ...........................................................................................2263 Failure code [879CKB] Ventilating Sensor Short Circuit ..........................................................................................2265 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .....................................................................................2267 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................2269 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................2272 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ............................................2275 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................................................2278 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..........................................................2281 A-4 Troubleshooting for FRESH/RECIRC air changeover .............................................................................................2284 Troubleshooting with gauge pressure .............................................................................................................2286 Connection of service tool ......................................................................................................................2289 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit .........................................................2291 Handling of compressor oil ......................................................................................................................2293 90 Diagrams and drawings ................................................................................................................................2295 Table of contents ...................................................................................................................................2296 Hydraulic circuit diagram ...........................................................................................................................2297 Symbols in hydraulic circuit diagram ............................................................................................................2297 Power train hydraulic circuit diagram ...........................................................................................................2301 Hydraulic circuit diagram .......................................................................................................................2321 Electric circuit diagram ............................................................................................................................2303 Symbols in electric circuit diagram .............................................................................................................2303 Electric circuit diagram of machine body (1/6) (North America specification).....................................................................2322 Electric circuit diagram of machine body (2/6) (Common to all specifications)....................................................................2323 Electric circuit diagram of machine body (3/6) (Common to all specifications and partially North America specification)..........................2324 Electric circuit diagram of machine body (4/6) (Common to all specifications)....................................................................2325 Electric circuit diagram of machine body (5/6) (Common to all specifications and partially North America specification)..........................2326 Electric circuit diagram of machine body (6/6) (EU specification)................................................................................2327 Electric circuit diagram of floor (1/8)..........................................................................................................2328 Electric circuit diagram of floor (2/8)..........................................................................................................2329 Electric circuit diagram of floor (3/8)..........................................................................................................2330 Electric circuit diagram of floor (4/8)..........................................................................................................2331 Electric circuit diagram of floor (5/8)..........................................................................................................2332 Electric circuit diagram of floor (6/8)..........................................................................................................2333 Electric circuit diagram of floor (7/8)..........................................................................................................2334 Electric circuit diagram of floor (8/8)..........................................................................................................2335 Electric circuit diagram of floor (1/8) (EU specification).......................................................................................2336 Electric circuit diagram of floor (2/8) (EU specification).......................................................................................2337 Electric circuit diagram of floor (3/8) (EU specification).......................................................................................2338 Electric circuit diagram of floor (4/8) (EU specification).......................................................................................2339 Electric circuit diagram of floor (5/8) (EU specification).......................................................................................2340 Electric circuit diagram of floor (6/8) (EU specification).......................................................................................2341 Electric circuit diagram of floor (7/8) (EU specification).......................................................................................2342 Electric circuit diagram of floor (8/8) (EU specification).......................................................................................2343 Circuit diagram of Central Lubrication System (CLS)..................................................................................................2344
DESCRIPTION:
KOMATSU WA380-7 WHEEL LOADER SHOP MANUAL VENBM40500 – PDF DOWNLOAD
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, forklift truck, service car, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 25/12/24
