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Komatsu WA470-7 Wheel Loader Shop Manual A47001 and up – PDF DOWNLOAD
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Description
Komatsu WA470-7 Wheel Loader Shop Manual A47001 and up
FILE DETAILS:
Komatsu WA470-7 Wheel Loader Shop Manual A47001 and up
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA470-7
Serial Number: A47001 and up
Book Code: CEBM027200
Language: English
Pages: 2346
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA470-7 Wheel Loader Shop Manual A47001 and up
How to read the shop manual:
Composition of shop manual:
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are described. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
Komatsu WA470-7 Wheel Loader Shop Manual A47001 and up
CEBM027200 - WA470-7 s/n A47001 - and up..................................................................................................................... 1 00 Index and foreword ................................................................................................................................... 3 Index ............................................................................................................................................... 4 Foreword, safety and general information ............................................................................................................ 20 Important safety notice ......................................................................................................................... 20 How to read the shop manual ..................................................................................................................... 27 Explanation of terms for maintenance standard ................................................................................................... 29 Handling equipment of fuel system devices ....................................................................................................... 31 Handling of intake system parts ................................................................................................................. 32 Handling of hydraulic equipment ................................................................................................................. 33 Method of disconnecting and connecting of push-pull type coupler ................................................................................ 35 Handling of electrical equipment ................................................................................................................ 38 How to read electric wire code .................................................................................................................. 46 Precautions when performing operation ........................................................................................................... 49 Practical use of KOMTRAX ........................................................................................................................ 53 Standard tightening torque table ................................................................................................................ 54 List of abbreviation ............................................................................................................................ 58 Conversion table ................................................................................................................................ 63 01 Specification ........................................................................................................................................ 69 Table of contents ................................................................................................................................... 70 Specifications ...................................................................................................................................... 71 Specification drawing ........................................................................................................................... 71 Specifications .................................................................................................................................. 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 ....................................................................................................................... 94 EGR system circuit diagram ...................................................................................................................... 96 EGR valve ....................................................................................................................................... 97 EGR cooler ...................................................................................................................................... 99 KCCV layout drawing ............................................................................................................................. 101 KCCV ventilator ................................................................................................................................. 103 KDPF ............................................................................................................................................ 105 Cooling system .................................................................................................................................. 109 Cooling fan pump ................................................................................................................................ 112 Cooling fan motor ............................................................................................................................... 121 Power train ......................................................................................................................................... 128 Power train system .............................................................................................................................. 128 Drive shaft ..................................................................................................................................... 131 Power train piping drawing ...................................................................................................................... 132 Transmission control ............................................................................................................................ 133 Torque converter ................................................................................................................................ 136 Transmission .................................................................................................................................... 141 Transmission control valve ...................................................................................................................... 160 Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV ..................................................................................... 163 3rd, 4th clutch ECMV ............................................................................................................................ 170 Lockup clutch ECMV .............................................................................................................................. 177 Main relief and torque converter relief valve ................................................................................................... 181 Axle ............................................................................................................................................ 183 Differential .................................................................................................................................... 185 Final drive ..................................................................................................................................... 195 Steering system ..................................................................................................................................... 197 Layout of steering parts ........................................................................................................................ 197 Steering column ................................................................................................................................. 198 Steering pump ................................................................................................................................... 199 Steering valve .................................................................................................................................. 211 Orbit-roll valve ................................................................................................................................ 225 Stop valve ...................................................................................................................................... 231 Emergency steering motor ........................................................................................................................ 232 Emergency steering pump ......................................................................................................................... 233 Brake system ........................................................................................................................................ 234 Layout of brake parts ........................................................................................................................... 234 Charge valve .................................................................................................................................... 236 Brake valve ..................................................................................................................................... 242 Slack adjuster .................................................................................................................................. 246 Accumulator (for brake) ......................................................................................................................... 249 Brake ........................................................................................................................................... 250 Parking brake control ........................................................................................................................... 253 Parking brake ................................................................................................................................... 254 Parking brake solenoid valve .................................................................................................................... 255 Parking brake emergency release valve ........................................................................................................... 258 Undercarriage and frame ............................................................................................................................. 259 Axle mount and center hinge pin ................................................................................................................. 259 Tire ............................................................................................................................................ 260 Hydraulic system .................................................................................................................................... 262 Hydraulic component layout ...................................................................................................................... 262 Work equipment control .......................................................................................................................... 264 Hydraulic tank .................................................................................................................................. 265 Double type gear pump ........................................................................................................................... 268 Work equipment pump ............................................................................................................................. 269 Control valve ................................................................................................................................... 290 CLSS ............................................................................................................................................ 299 Hydraulic circuit diagram and names of valves ................................................................................................... 303 Accumulator charge valve ........................................................................................................................ 314 Work equipment lock solenoid valve .............................................................................................................. 318 Accumulator (for PPC circuit) ................................................................................................................... 319 Accumulator (for ECSS) .......................................................................................................................... 320 Work equipment ...................................................................................................................................... 321 Work equipment linkage .......................................................................................................................... 321 Bucket .......................................................................................................................................... 322 Bucket positioner and boom positioner ........................................................................................................... 323 Cab and its attachments ............................................................................................................................. 324 ROPS cab ........................................................................................................................................ 324 Electrical system ................................................................................................................................... 325 Engine control system ........................................................................................................................... 325 Preheating system ............................................................................................................................... 327 Engine power mode selector circuit .............................................................................................................. 329 Engine output limit function .................................................................................................................... 330 Automatic warm-up function ...................................................................................................................... 331 Parking brake control system .................................................................................................................... 332 System operating lamp function .................................................................................................................. 334 Battery disconnect switch function .............................................................................................................. 336 Transmission controller system .................................................................................................................. 338 Work equipment control system ................................................................................................................... 359 Machine monitor system .......................................................................................................................... 375 Rear view monitor system ........................................................................................................................ 399 KOMTRAX system .................................................................................................................................. 402 System component parts .......................................................................................................................... 405 Sensor .......................................................................................................................................... 432 20 Standard value tables ................................................................................................................................ 461 Table of contents ................................................................................................................................... 462 Standard service value table ........................................................................................................................ 463 Standard value table for engine ................................................................................................................. 463 Standard value table for machine ................................................................................................................ 465 Standard value table for electrical system ...................................................................................................... 478 30 Testing and adjusting ................................................................................................................................ 493 Table of contents ................................................................................................................................... 494 General information on testing and adjusting ........................................................................................................ 496 Tools for testing and adjusting ................................................................................................................. 496 Sketch of tools for testing and adjusting ....................................................................................................... 500 Engine and cooling system ........................................................................................................................... 502 Testing engine speed ............................................................................................................................ 502 Testing boost pressure .......................................................................................................................... 504 Testing exhaust gas color ....................................................................................................................... 506 Testing and adjusting valve clearance ........................................................................................................... 508 Testing compression pressure .................................................................................................................... 510 Testing blowby pressure ......................................................................................................................... 514 Testing engine oil pressure ..................................................................................................................... 516 Testing EGR valve and KVGT oil pressures ........................................................................................................ 517 Testing fuel pressure ........................................................................................................................... 518 Testing fuel return rate and leakage ............................................................................................................ 519 Bleeding air from fuel system ................................................................................................................... 523 Testing fuel circuit for leakage ................................................................................................................ 525 Handling cylinder cutout mode operation ......................................................................................................... 526 Handling no injection cranking operation ........................................................................................................ 527 Testing of KDPF and muffler stack for looseness and damage ...................................................................................... 528 Testing of installed condition of cylinder head and manifolds ................................................................................... 529 Testing engine piping for damage and looseness .................................................................................................. 530 Testing and adjusting air conditioner compressor belt tension ................................................................................... 531 Testing and adjusting alternator belt tension ................................................................................................... 533 Procedures for cleaning fuel doser .............................................................................................................. 535 Writing compensation values at replacement of injector and engine controller .................................................................... 538 Power train ......................................................................................................................................... 542 Adjusting transmission output speed sensor ...................................................................................................... 542 Adjusting transmission input speed sensor ....................................................................................................... 543 Flushing procedure for torque converter and transmission hydraulic circuit ...................................................................... 544 Retrieval of disabled machine due to transmission valve failure ................................................................................. 546 Testing oil leakage from axle final drive ....................................................................................................... 548 Testing drive shaft for looseness, backlash, and damage ......................................................................................... 549 Testing and adjusting power train oil pressure .................................................................................................. 550 Steering system ..................................................................................................................................... 565 Testing directional lever ....................................................................................................................... 565 Testing steering wheel .......................................................................................................................... 566 Testing work equipment control lever ............................................................................................................ 568 Testing and adjusting steering circuit oil pressure ............................................................................................. 570 Bleeding air from steering cylinder circuit. .................................................................................................... 573 Testing and adjusting steering stopper valve .................................................................................................... 574 Brake system ........................................................................................................................................ 575 Testing brake pedal ............................................................................................................................. 575 Testing and adjusting brake pedal linkage ....................................................................................................... 576 Testing braking performance ..................................................................................................................... 577 Testing and adjusting of accumulator charge pressure ............................................................................................ 578 Testing of brake accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas ............................... 580 Testing wheel brake oil pressure ................................................................................................................ 584 Testing lowering of wheel brake pressure ........................................................................................................ 586 Testing wear of wheel brake disc ................................................................................................................ 588 Bleeding air from wheel brake circuit ........................................................................................................... 589 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 .............................................................................................................. 594 Method of releasing parking brake manually ...................................................................................................... 595 Hydraulic system .................................................................................................................................... 597 Testing fan speed ............................................................................................................................... 597 Testing fan pump circuit oil pressure ........................................................................................................... 598 Bleeding air from hydraulic fan circuit ......................................................................................................... 600 Testing and adjusting work equipment EPC oil pressure ........................................................................................... 602 Testing and adjusting work equipment oil pressure ............................................................................................... 605 Bleeding air from work equipment circuit ........................................................................................................ 609 Releasing remaining pressure from work equipment circuit ........................................................................................ 610 Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ...................................... 611 Work equipment ...................................................................................................................................... 615 Testing and adjusting bucket position detection lever ........................................................................................... 615 Testing and adjusting boom position detection lever ............................................................................................. 616 Electrical system ................................................................................................................................... 617 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor .......................................................... 617 Special functions of machine monitor ............................................................................................................ 619 Adjusting rearview camera angle ................................................................................................................. 708 Handling voltage circuit of engine controller ................................................................................................... 709 Handling battery disconnect switch .............................................................................................................. 710 Testing diodes .................................................................................................................................. 711 Pm clinic ........................................................................................................................................... 712 Pm Clinic service ............................................................................................................................... 712 Check sheet ..................................................................................................................................... 713 40 Troubleshooting ...................................................................................................................................... 719 Table of contents ................................................................................................................................... 720 General information on troubleshooting .............................................................................................................. 729 Troubleshooting points .......................................................................................................................... 729 Sequence of events in troubleshooting ........................................................................................................... 731 Check before troubleshooting .................................................................................................................... 733 Inspection procedure before troubleshooting ..................................................................................................... 735 Preparation work for troubleshooting of electrical system ....................................................................................... 752 Classification and procedures for troubleshooting ............................................................................................... 758 Symptom and troubleshooting numbers ............................................................................................................. 761 Information in troubleshooting table ............................................................................................................ 764 Connector list and layout ....................................................................................................................... 766 Connector contact identification ................................................................................................................ 780 T-branch box and T-branch adapter table ......................................................................................................... 816 Fuse location table ............................................................................................................................. 822 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................................................................... 825 Precautions on troubleshooting of machine monitor ............................................................................................... 828 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ......................................................... 830 Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................................. 835 Fabrication of short-circuit connector (for CA1883 and CA3135) .................................................................................. 836 Failure codes table ............................................................................................................................. 837 Troubleshooting by failure code (Display of code) ................................................................................................... 851 Failure code [1500L0] Double Engagement of T/M Clutches ......................................................................................... 851 Failure code [15SAL1] Release Trouble of ECMV (Forward) ......................................................................................... 852 Failure code [15SALH] Malfunction of ECMV (Forward) ............................................................................................. 854 Failure code [15SBL1] Release Trouble of ECMV (Reverse) ......................................................................................... 856 Failure code [15SBLH] Malfunction of ECMV (Reverse) ............................................................................................. 858 Failure code [15SEL1] Release Trouble of ECMV (1st) ............................................................................................. 860 Failure code [15SELH] Malfunction of ECMV (1st) ................................................................................................. 862 Failure code [15SFL1] Release Trouble of ECMV (2nd) ............................................................................................. 864 Failure code [15SFLH] Malfunction of ECMV (2nd) ................................................................................................. 866 Failure code [15SGL1] Release Trouble of ECMV (3rd) ............................................................................................. 868 Failure code [15SGLH] Malfunction of ECMV (3rd) ................................................................................................. 870 Failure code [15SHL1] Release Trouble of ECMV (4th) ............................................................................................. 872 Failure code [15SHLH] Malfunction of ECMV (4th) ................................................................................................. 874 Failure code [2F00MA] Failure of Parking Brake Circuit .......................................................................................... 876 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...................................................................................... 880 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....................................................................................... 882 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................................. 884 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................ 885 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................................. 886 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................ 887 Failure code [879CKA] Ventilating Sensor Open Circuit ........................................................................................... 888 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................................................... 889 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..................................................................................... 890 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................ 891 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................ 892 Failure code [989A00] Engine Overrun Prevention Activated ....................................................................................... 893 Failure code [989L00] Engine Controller Lock Caution 1 .......................................................................................... 894 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................................... 895 Failure code [989N00] Engine Controller Lock Caution 3 .......................................................................................... 896 Failure code [A1U0N3] HC Desorb Request 1 ....................................................................................................... 897 Failure code [A1U0N4] HC Desorb Request 2 ....................................................................................................... 899 Failure code [AA10NX] Air Cleaner Clogging ...................................................................................................... 901 Failure code [B@BAZG] Eng Oil Press Low ......................................................................................................... 903 Failure code [B@BAZK] Eng Oil Level Low ......................................................................................................... 904 Failure code [B@BCNS] Eng Water Overheat ........................................................................................................ 906 Failure code [B@BCZK] Eng Water Level Low ....................................................................................................... 907 Failure code [B@CENS] T/C Oil Temp. Overheat .................................................................................................... 909 Failure code [B@HANS] HYD Oil Temp. Overheat .................................................................................................... 910 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................................... 911 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................................ 912 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................................. 914 Failure code [CA131] Throttle Sensor High Error ................................................................................................. 916 Failure code [CA132] Throttle Sensor Low Error .................................................................................................. 918 Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................................ 920 Failure code [CA141] Eng Oil Press Sensor Low Error ............................................................................................. 922 Failure code [CA144] Coolant Temp Sens High Error ............................................................................................... 924 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................................ 926 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................................. 928 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................................. 930 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................................. 932 Failure code [CA221] Ambient Press Sensor High Error ............................................................................................ 934 Failure code [CA222] Ambient Press Sensor Low Error ............................................................................................. 936 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................................ 938 Failure code [CA234] Eng Overspeed .............................................................................................................. 939 Failure code [CA238] Ne Speed Sensor Supply Volt Error .......................................................................................... 940 Failure code [CA239] Ne Speed Sens Supply Volt High Error ....................................................................................... 941 Failure code [CA271] IMV/PCV1 Short Error ....................................................................................................... 942 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................................ 943 Failure code [CA273] PCV2 Short Error ........................................................................................................... 944 Failure code [CA274] PCV2 Open Error ............................................................................................................ 945 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................................................... 946 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................................................... 948 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................................................... 950 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................................................... 952 Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................................................... 954 Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................................................... 956 Failure code [CA343] ECM Critical Internal Failure .............................................................................................. 958 Failure code [CA351] Injectors Drive Circuit Error .............................................................................................. 959 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................................. 960 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................................ 962 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................................. 964 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................................ 966 Failure code [CA431] Idle Validation Sw Error ................................................................................................... 967 Failure code [CA432] Idle Validation Process Error .............................................................................................. 970 Failure code [CA441] Battery Voltage Low Error .................................................................................................. 973 Failure code [CA442] Battery Voltage High Error ................................................................................................. 975 Failure code [CA449] Rail Press Very High Error ................................................................................................. 976 Failure code [CA451] Rail Press Sensor High Error ............................................................................................... 977 Failure code [CA452] Rail Press Sensor Low Error ................................................................................................ 979 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................................ 981 Failure code [CA516] Rail Press Sens Sup Volt Low Error ......................................................................................... 983 Failure code [CA553] Rail Press High Error ...................................................................................................... 985 Failure code [CA555] Crankcase Press High Error 1 ............................................................................................... 986 Failure code [CA556] Crankcase Press High Error 2 ............................................................................................... 987 Failure code [CA559] Rail Press Low Error ....................................................................................................... 988 Failure code [CA595] Turbo Speed High Error 2 ................................................................................................... 992 Failure code [CA687] Turbo Speed Low Error ...................................................................................................... 993 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................................. 995 Failure code [CA691] Intake Air Temp Sens High Error ............................................................................................ 997 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................................. 999 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................................1001 Failure code [CA698] ECM Int Temp Sensor Low Error ..............................................................................................1002 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................................1003 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................................1004 Failure code [CA1117] Persistent Data Lost Error ................................................................................................1006 Failure code [CA1664] KDOC Malfunction ..........................................................................................................1007 Failure code [CA1691] Regeneration Ineffective ..................................................................................................1010 Failure code [CA1695] Sensor 5 Supply Volt High Error ...........................................................................................1013 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................................................1014 Failure code [CA1843] Crankcase Press Sens High Error ...........................................................................................1016 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................................................1018 Failure code [CA1879] KDPF Delta P Sensor High Error ............................................................................................1020 Failure code [CA1881] KDPF Delta P Sensor Low Error .............................................................................................1022 Failure code [CA1883] KDPF Delta P Sens In Range Error ..........................................................................................1024 Failure code [CA1921] KDPF Soot Load High Error 1 ...............................................................................................1027 Failure code [CA1922] KDPF Soot Load High Error 2 ...............................................................................................1030 Failure code [CA1923] Dosing Fuel Valve 1 High Error ............................................................................................1035 Failure code [CA1924] Dosing Fuel Valve 1 Low Error .............................................................................................1037 Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ........................................................................................1040 Failure code [CA1927] Dosing Fuel Press Sens High Error .........................................................................................1042 Failure code [CA1928] Dosing Fuel Press Sens Low Error ..........................................................................................1044 Failure code [CA1942] Crankcase Press Sens In Range Error .......................................................................................1046 Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...........................................................................................1047 Failure code [CA1977] Fuel Doser Open/Short Error ...............................................................................................1049 Failure code [CA1993] KDPF Delta Pressure Low Error .............................................................................................1051 Failure code [CA2185] Throt Sensor Sup Volt High Error ..........................................................................................1053 Failure code [CA2186] Throt Sensor Sup Volt Low Error ...........................................................................................1055 Failure code [CA2249] Rail Press Very Low Error .................................................................................................1057 Failure code [CA2265] Fuel Feed Pump Open Error .................................................................................................1058 Failure code [CA2266] Fuel Feed Pump Short Error ................................................................................................1060 Failure code [CA2271] EGR Valve Pos Sens High Error .............................................................................................1062 Failure code [CA2272] EGR Valve Pos Sens Low Error ..............................................................................................1064 Failure code [CA2349] EGR Valve Solenoid Open Error .............................................................................................1066 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................................1068 Failure code [CA2357] EGR Valve Servo Error .....................................................................................................1070 Failure code [CA2381] KVGT Pos Sens High Error ..................................................................................................1071 Failure code [CA2382] KVGT Pos Sens Low Error ...................................................................................................1073 Failure code [CA2383] KVGT Solenoid Open Error ..................................................................................................1075 Failure code [CA2386] KVGT Solenoid Short Error .................................................................................................1077 Failure code [CA2387] KVGT Servo Error ..........................................................................................................1079 Failure code [CA2555] Grid Htr Relay Volt Low Error .............................................................................................1080 Failure code [CA2556] Grid Htr Relay Volt High Error ............................................................................................1082 Failure code [CA2637] KDOC Face Plugging ........................................................................................................1084 Failure code [CA2639] Manual Stationary Regeneration Request ....................................................................................1086 Failure code [CA2732] Dosing Fuel Valve 2 High Error ............................................................................................1089 Failure code [CA2733] Dosing Fuel Valve 2 Low Error .............................................................................................1091 Failure code [CA2741] Dosing Fuel Valve Swap Error ..............................................................................................1093 Failure code [CA2765] Inj Trim Data Error .......................................................................................................1095 Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...........................................................................................1096 Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ..........................................................................................1099 Failure code [CA3133] KDPF Outlet Press Sens High Error .........................................................................................1104 Failure code [CA3134] KDPF Outlet Press Sens Low Error ..........................................................................................1106 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .....................................................................................1108 Failure code [CA3167] Fuel Doser Degradation ....................................................................................................1111 Failure code [CA3251] KDOC Inlet Temp High Error ................................................................................................1114 Failure code [CA3253] KDOC Temp Error - Non Regeneration ........................................................................................1117 Failure code [CA3254] KDOC Outlet Temp High Error 1 .............................................................................................1120 Failure code [CA3255] KDPF Temp Error - Non Regeneration ........................................................................................1123 Failure code [CA3256] KDPF Outlet Temp High Error 1 .............................................................................................1127 Failure code [CA3311] KDOC Outlet Temp High Error 2 .............................................................................................1130 Failure code [CA3312] KDPF Outlet Temp High Error 2 .............................................................................................1133 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ..........................................................................................1136 Failure code [CA3314] KDOC Inlet Temp Sens High Error ...........................................................................................1139 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .......................................................................................1143 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...........................................................................................1148 Failure code [CA3317] KDOC Outlet Temp Sens High Error ..........................................................................................1151 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ......................................................................................1155 Failure code [CA3319] KDPF Outlet Temp Sens High Error ..........................................................................................1160 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...........................................................................................1164 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ......................................................................................1167 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ..................................................................................1172 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...................................................................................1174 Failure code [D150KA] Disconnection of Emerg. Steering Relay ....................................................................................1176 Failure code [D150KB] Ground Fault of Emerg. Steering Relay .....................................................................................1178 Failure code [D150KY] Hot Short of Emergency Steering Relay .....................................................................................1180 Failure code [D160KA] Disconnection of Backup Lamp Relay Output .................................................................................1182 Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ..................................................................................1184 Failure code [D160KY] Hot Short of Backup Lamp Relay Output .....................................................................................1186 Failure code [D191KA] Disconnection of Neutral Output Relay .....................................................................................1188 Failure code [D191KB] Ground Fault of Neutral Output Relay ......................................................................................1190 Failure code [D191KY] Hot Short of Neutral Output Relay .........................................................................................1192 Failure code [D192KA] Disconnection of ECSS Solenoid ............................................................................................1194 Failure code [D192KB] Ground Fault of ECSS Solenoid .............................................................................................1196 Failure code [D192KY] Hot Short of ECSS Solenoid ................................................................................................1197 Failure code [D19JKZ] Personal Code Relay Abnormality ...........................................................................................1198 Failure code [D1E6KA] Disconnection of Parking Brake Relay ......................................................................................1200 Failure code [D1E6KB] Ground Fault of Parking Brake Relay .......................................................................................1202 Failure code [D1E6KY] Hot Short of Parking Brake Relay ..........................................................................................1204 Failure code [D5ZHKA] Failure of Key SW C Signal ................................................................................................1206 Failure code [D5ZHKB] Key SW C Signal Short Circuit .............................................................................................1208 Failure code [D5ZHKZ] Failure of Key SW C Signal ................................................................................................1210 Failure code [D5ZHL6] Disconnection of Key SW C .................................................................................................1212 Failure code [D811MC] KOMTRAX Error .............................................................................................................1214 Failure code [D862KA] GPS Antenna Open Circuit ..................................................................................................1215 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .....................................................................................1216 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ....................................................................................1218 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...................................................................................................1220 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .....................................................................................................1221 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................................................................1223 Failure code [DAF0MB] Monitor ROM Abnormality ...................................................................................................1224 Failure code [DAF0MC] Monitor Error .............................................................................................................1225 Failure code [DAF3KK] Controller Power Source Low (MON) .........................................................................................1226 Failure code [DAF8KB] Camera Power Supply Short Circuit .........................................................................................1228 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ....................................................................................1229 Failure code [DAFGMC] GPS Module Error ..........................................................................................................1231 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) .........................................................................................1232 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ........................................................................................1234 Failure code [DAFQKR] CAN2 Discon (Monitor) .....................................................................................................1236 Failure code [DAQ0KK] Controller Power Source Low (T/M) .........................................................................................1237 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ..................................................................................1240 Failure code [DAQ0MC] T/M Con Error .............................................................................................................1241 Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .........................................................................................1242 Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ...........................................................................................1244 Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ...................................................................................1247 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ....................................................................................1249 Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) .........................................................................................1250 Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ........................................................................................1252 Failure code [DAQQKR] CAN2 Discon (Transmission Con) ............................................................................................1254 Failure code [DAQRKR] CAN1 Discon (Transmission Con) ............................................................................................1255 Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ...................................................................................1256 Failure code [DAZ9KQ] A/C Model Selection Abnormality ...........................................................................................1257 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ..................................................................................................1258 Failure code [DB2QKR] CAN2 Discon (Engine Con) ..................................................................................................1259 Failure code [DB2RKR] CAN1 Discon (Engine Con) ..................................................................................................1264 Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................................................................1269 Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ..................................................................................1271 Failure code [DB90MC] BBC Error .................................................................................................................1272 Failure code [DB91KA] Disconnection of Key SW ACC (BBC) .........................................................................................1273 Failure code [DB92KK] Solenoid Power Source Low (BBC) ...........................................................................................1275 Failure code [DB95KX] Failure of 5 V Power Source 1 .............................................................................................1277 Failure code [DB96KX] Failure of 5 V Power Source 2 .............................................................................................1279 Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ....................................................................................1281 Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) .........................................................................................1282 Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ........................................................................................1284 Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .............................................................................................1286 Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .............................................................................................1287 Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ...................................................................................1288 Failure code [DBE5KX] Failure of 5V Power Source ................................................................................................1289 Failure code [DBE6KX] Failure of 24 V Power Source ..............................................................................................1291 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................................................................1293 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................................................................1295 Failure code [DDB6L4] Neutral Signal Malfunction ................................................................................................1297 Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ...................................................................................1300 Failure code [DDK3KA] FNR SW Input Signal Disconnection .........................................................................................1302 Failure code [DDK3KB] FNR SW Input Signal Short Circuit .........................................................................................1305 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ......................................................................................1307 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ......................................................................................1310 Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................................................................1312 Failure code [DDT0L4] Failure of Shift Mode Select SW ...........................................................................................1314 Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal .................................................................................1316 Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal .....................................................................................1318 Failure code [DDW9LD] Ground Fault of Kickdown Switch ...........................................................................................1320 Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW .........................................................................................1322 Failure code [DF10KA] Disconnection of Shift Lever Input ........................................................................................1324 Failure code [DF10KB] Ground Fault of Shift Lever Input .........................................................................................1326 Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor .....................................................................................1329 Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ......................................................................................1331 Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ......................................................................................1333 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ....................................................................................1335 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .........................................................................................1336 Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor .....................................................................................1338 Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ......................................................................................1341 Failure code [DH21KA] Failure of Loader Pump Press. Sensor ......................................................................................1343 Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ...................................................................................1345 Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit .....................................................................................1347 Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor .................................................................................1349 Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ...................................................................................1351 Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor .................................................................................1353 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .................................................................................1355 Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ................................................................................1357 Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ....................................................................................1359 Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit .................................................................................1361 Failure code [DHT8ZG] Steering Oil Pressure Low .................................................................................................1363 Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ...................................................................................1364 Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ....................................................................................1366 Failure code [DJF1KA] Disconnection of Fuel Level Sensor ........................................................................................1368 Failure code [DK55KA] Failure of FNR Lever Potentio .............................................................................................1370 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...................................................................................1373 Failure code [DK55L5] Failure of FNR Lever Potentio .............................................................................................1375 Failure code [DK59KA] Failure of Boom Lever Potentio (Main) .....................................................................................1376 Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ...................................................................................1379 Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................................................................1382 Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ......................................................................................1386 Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ....................................................................................1389 Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ...................................................................................1392 Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) .................................................................................1395 Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................................................................1398 Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ....................................................................................1402 Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ..................................................................................1405 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ......................................................................................1408 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ....................................................................................1411 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ..................................................................................1413 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) .......................................................................................1416 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) .....................................................................................1419 Failure code [DKA0KA] Failure of Boom Angle Sensor ..............................................................................................1421 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ....................................................................................1423 Failure code [DKA0L0] Boom Angle Sensor Dislocation .............................................................................................1425 Failure code [DKA1KA] Failure of Bucket Angle Sensor ............................................................................................1427 Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ..................................................................................1429 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ...................................................................................1431 Failure code [DLF1LC] Failure of T/M Input Speed Sensor .........................................................................................1433 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ................................................................................1435 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ......................................................................................1437 Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ................................................................................1439 Failure code [DLT3LC] Failure of Output Speed Sensor (Main) .....................................................................................1441 Failure code [DPQ1KR] LIN Discon (Switch Panel) .................................................................................................1443 Failure code [DPQ2KR] LIN Discon (LED Unit) .....................................................................................................1446 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ............................................................................................1449 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ..................................................................................................1452 Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .....................................................................................1454 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...................................................................................1456 Failure code [DV00KB] Ground Fault of Buzzer Output .............................................................................................1458 Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................................................................1460 Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) .................................................................................1462 Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................................................................1464 Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ................................................................................1466 Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) .................................................................................1468 Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ....................................................................................1470 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...................................................................................1472 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ................................................................................1474 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...................................................................................1476 Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ...................................................................................1478 Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................................................................1480 Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ...................................................................................1482 Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid .....................................................................................1484 Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ....................................................................................1486 Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. .......................................................................................1488 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ....................................................................................1489 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid .....................................................................................1491 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ........................................................................................1493 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................................................................1495 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ....................................................................................1497 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) .......................................................................................1499 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) .................................................................................1501 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ..................................................................................1503 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) .....................................................................................1505 Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ...................................................................................1507 Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................................................................1509 Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ...................................................................................1511 Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid .................................................................................1513 Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ..................................................................................1515 Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid .....................................................................................1517 Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...................................................................................1519 Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ................................................................................1521 Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid ...................................................................................1523 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ...................................................................................1524 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................................................................1526 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .......................................................................................1528 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ......................................................................................1530 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) .......................................................................................1532 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ..........................................................................................1534 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ......................................................................................1536 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .......................................................................................1538 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ..........................................................................................1540 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ......................................................................................1542 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) .......................................................................................1544 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ..........................................................................................1546 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ..................................................................................1548 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ...................................................................................1550 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ......................................................................................1552 Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ..................................................................................1554 Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ...................................................................................1556 Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ......................................................................................1558 Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ......................................................................................1560 Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) .......................................................................................1562 Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ..........................................................................................1564 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...................................................................................1566 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ....................................................................................1568 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .......................................................................................1570 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................................................................1572 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ....................................................................................1574 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) .......................................................................................1576 Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor ....................................................................................1578 Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor ....................................................................................1581 Failure code [DY30ME] Emerg. Steering Long-Time Activated .......................................................................................1585 Failure code [LA00L3] Failure of Fan Reverse ....................................................................................................1587 Troubleshooting of electrical system (E-mode) .......................................................................................................1588 E-1 Engine does not start .......................................................................................................................1588 E-2 Manual preheating system does not work ......................................................................................................1594 E-3 Automatic preheating system does not work ...................................................................................................1597 E-4 While preheating is working, preheating monitor does not light up ...........................................................................1599 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ................................................................1601 E-6 LCD unit on machine monitor displays nothing ................................................................................................1604 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) .......................................................1606 E-8 LCD on machine monitor does not display properly ............................................................................................1608 E-9 Meter unit display on machine monitor is abnormal ...........................................................................................1610 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...........................................................................1613 E-11 Caution LED on machine monitor is abnormal .................................................................................................1616 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...................................................1618 E-13 Two switches operation of switch panel on machine monitor does not function ................................................................1620 E-14 Switch panel buzzer of machine monitor is abnormal .........................................................................................1623 E-15 Rear view monitor does not light up or backlight flickers ..................................................................................1625 E-16 Rear view monitor images are not displayed clearly .........................................................................................1628 E-17 Rear view monitor brightness cannot be adjusted ............................................................................................1631 E-18 Night lighting lamp of rear view monitor is abnormal .......................................................................................1634 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly .......................................................1636 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position .........................................1637 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ..............................................1641 E-22 Air cleaner clogging indicator lamp does not light .........................................................................................1643 E-23 Radiator coolant level caution lamp does not light .........................................................................................1644 E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ..................1646 E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ....1648 E-26 Fuel level gauge does not indicate correct level ...........................................................................................1649 E-27 Seat belt caution lamp indication is abnormal ..............................................................................................1651 E-28 Horn does not sound ........................................................................................................................1652 E-29 Horn does not stop sounding ................................................................................................................1655 E-30 Alarm buzzer does not sound ................................................................................................................1657 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................................................................1658 E-32 Kickdown does not work when kickdown switch is turned ON ...................................................................................1659 E-33 The hold switch does not work when it is pressed ...........................................................................................1661 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 ..............1663 E-35 Transmission cut-off mode is not selected or not released ..................................................................................1666 E-36 Transmission cut-off setting cannot be released ............................................................................................1668 E-37 Directional selector (FNR) switch mode is not selected or not released .....................................................................1670 E-38 When operating engine power selection switch, engine power selection function does not operate properly ....................................1672 E-39 Flow of loader pump does not increase from the minimum rate ................................................................................1674 E-40 ECSS function cannot be selected or cannot be released .....................................................................................1675 E-41 None of headlamp, clearance lamp, and tail lamp lights .....................................................................................1677 E-42 Clearance lamp and tail lamp do not light up or go out .....................................................................................1679 E-43 Both High and Low beams of headlamp do not light up or go out ..............................................................................1682 E-44 Low beam of headlamp does not light up or go out ...........................................................................................1686 E-45 High beam of headlamp does not light up or go out ..........................................................................................1688 E-46 Front working lamp does not light up or go out .............................................................................................1690 E-47 Rear working lamp does not light up or go out ..............................................................................................1693 E-48 All of turn signal lamps and hazard lamps do not light up or go out ........................................................................1696 E-49 Turn signal lamps do not light up or go out ................................................................................................1699 E-50 Hazard lamp does not light up or go out ....................................................................................................1702 E-51 Brake lamp does not light or stays lighted .................................................................................................1705 E-52 Backup lamp does not light up or does not go out ...........................................................................................1708 E-53 Backup buzzer does not sound or continues to sound .........................................................................................1711 E-54 Front wiper does not operate ...............................................................................................................1713 E-55 Rear wiper does not operate ................................................................................................................1716 E-56 Window washer does not operate .............................................................................................................1718 E-57 Fuel feed pump does not operate or stop automatically ......................................................................................1721 E-58 KOMTRAX system does not operate properly ...................................................................................................1723 Troubleshooting of hydraulic and mechanical system (H-mode) .........................................................................................1725 Information described in troubleshooting table (H-mode) .........................................................................................1725 System chart of hydraulic and mechanical systems ................................................................................................1726 Failure mode and cause table ....................................................................................................................1729 H-1 Machine does not move off ...................................................................................................................1737 H-2 Torque converter lockup clutch is not disengaged (engine stalls) ............................................................................1740 H-3 Torque converter lockup clutch is not engaged ...............................................................................................1741 H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift .........................................1742 H-5 Large shock is made when machine starts or gear is shifted ..................................................................................1745 H-6 Machine starts or gear speed shifts with long time lag ......................................................................................1747 H-7 Torque converter oil temperature is high ....................................................................................................1749 H-8 Machine does not turn .......................................................................................................................1751 H-9 Turning response is poor ....................................................................................................................1753 H-10 Steering wheel is heavy to turn ............................................................................................................1755 H-11 Machine sways or large shocks are made while machine turns .................................................................................1756 H-12 Turning radius differs between right and left turns ........................................................................................1758 H-13 Wheel brakes do not work or are weak .......................................................................................................1759 H-14 Wheel brakes are not released or drag ......................................................................................................1761 H-15 Parking brake does not work or it is weak ..................................................................................................1762 H-16 Parking brake is not released or drags (including emergency release system) ................................................................1763 H-17 Boom does not rise .........................................................................................................................1764 H-18 Boom moves slow or boom lacks lifting force ................................................................................................1766 H-19 Rising boom slows down at certain height ...................................................................................................1768 H-20 Lift cylinders do not serve to hold bucket on ground .......................................................................................1769 H-21 Hydraulic drift of boom is large ...........................................................................................................1770 H-22 Boom moves up and down during operation ....................................................................................................1771 H-23 Bucket does not tilt back ..................................................................................................................1772 H-24 Bucket moves slow or lacks tilt-back force .................................................................................................1774 H-25 Bucket decelerates during tilt-back operation ..............................................................................................1776 H-26 Bucket cylinder does not hold bucket on ground .............................................................................................1777 H-27 Hydraulic drift of bucket is large .........................................................................................................1778 H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ............................................................1779 H-29 Boom and bucket control levers do not move smoothly and are heavy to move ..................................................................1780 H-30 Operating work equipment causes engine speed to lower significantly or engine to stall .....................................................1781 H-31 Large shocks are made when work equipment starts to move and stops .........................................................................1782 H-32 When certain work equipment stalls hydraulically, other work equipment moves ...............................................................1784 H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces .....................................................................1785 H-34 Bucket does not stop at the position which is set with remote bucket positioner ............................................................1786 H-35 Fan speed is abnormal (too high or low, or fan does not rotate) ............................................................................1787 H-36 Unusual noise is heard from around fan .....................................................................................................1788 Troubleshooting of engine (S-mode) ..................................................................................................................1789 Information mentioned in troubleshooting table (S mode) .........................................................................................1789 S-1 When starting switch is turned to START position, engine is not cranked .....................................................................1790 S-2 The engine cranks but exhaust smoke does not come out .......................................................................................1791 S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ......................................1792 S-4 Engine startability is poor .................................................................................................................1793 S-5 Engine does not pick-up smoothly ............................................................................................................1795 S-6 Engine stops during operation ...............................................................................................................1797 S-7 Engine runs rough or is unstable ............................................................................................................1799 S-8 Engine lacks power ..........................................................................................................................1800 S-9 KDPF gets clogged in a short time ...........................................................................................................1802 S-10 Engine oil consumption is excessive ........................................................................................................1804 S-11 Engine oil becomes contaminated early ......................................................................................................1805 S-12 Fuel consumption is excessive ..............................................................................................................1806 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...........................................................................1807 S-14 Oil pressure drops .........................................................................................................................1808 S-15 Fuel mixes into engine oil .................................................................................................................1809 S-16 Water mixes into engine oil (milky) ........................................................................................................1810 S-17 Coolant temperature rises too high (overheating) ...........................................................................................1811 S-18 Unusual noise is heard .....................................................................................................................1812 S-19 Vibration is excessive .....................................................................................................................1813 S-20 Air cannot be bled from fuel circuit .......................................................................................................1814 S-21 Active regeneration is executed frequently .................................................................................................1815 S-22 Active regeneration takes a long time ......................................................................................................1816 S-23 White smoke is exhausted during active regeneration ........................................................................................1817 50 Disassembly and assembly .............................................................................................................................1819 Table of contents ...................................................................................................................................1820 General information on disassembly and assembly .....................................................................................................1822 How to read this manual .........................................................................................................................1822 Coating materials list ..........................................................................................................................1824 Special tools list ..............................................................................................................................1828 Sketches of special tools .......................................................................................................................1835 Engine and cooling system ...........................................................................................................................1865 Removal and installation of supply pump assembly ................................................................................................1865 Removal and installation of injector assembly ...................................................................................................1871 Removal and installation of fuel doser assembly .................................................................................................1879 Removal and installation of cylinder head assembly ..............................................................................................1881 Removal and installation of engine hood assembly ................................................................................................1895 Removal and installation of grille assembly .....................................................................................................1897 Removal and installation of cooling system assembly .............................................................................................1900 Removal and installation of radiator core assembly ..............................................................................................1903 Removal and installation of aftercooler .........................................................................................................1905 Removal and installation of hydraulic oil cooler ................................................................................................1908 Removal and installation of power train oil cooler assembly .....................................................................................1910 Removal and installation of engine assembly .....................................................................................................1914 Removal and installation of engine front oil seal ...............................................................................................1920 Removal and installation of engine rear oil seal ................................................................................................1923 Removal and installation of cooling fan and cooling fan motor assembly ..........................................................................1928 Removal and installation of KDPF assembly .......................................................................................................1930 Disassembly and assembly of KDPF assembly .......................................................................................................1935 Removal and installation of KCCV assembly .......................................................................................................1944 Removal and installation of KVGT assembly .......................................................................................................1946 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ......................................................................1951 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .....................................................................1952 Removal and installation of air cleaner assembly ................................................................................................1954 Removal and installation of air conditioner compressor belt .....................................................................................1956 Removal and installation of alternator belt .....................................................................................................1957 Removal and installation of fuel tank assembly ..................................................................................................1958 Power train .........................................................................................................................................1961 Removal and installation of torque converter and transmission assembly ..........................................................................1961 Disassembly and assembly of transmission assembly ...............................................................................................1966 Disassembly and assembly of torque converter assembly ...........................................................................................1996 Disassembly and assembly of transmission clutch pack assembly ...................................................................................2003 Removal and installation of front axle assembly .................................................................................................2026 Removal and installation of rear axle assembly ..................................................................................................2028 Disassembly and assembly of axle housing assembly ...............................................................................................2033 Disassembly and assembly of differential assembly ...............................................................................................2043 Steering system .....................................................................................................................................2062 Removal and installation of steering valve assembly .............................................................................................2062 Brake system ........................................................................................................................................2064 Removal and installation of brake charge valve assembly .........................................................................................2064 Removal and installation of parking brake disc and plate ........................................................................................2065 Undercarriage and frame .............................................................................................................................2068 Removal and installation of center hinge pin ....................................................................................................2068 Removal and installation of counterweight assembly ..............................................................................................2076 Removal and installation of full-length fender assembly .........................................................................................2078 Hydraulic system ....................................................................................................................................2079 Removal and installation of hydraulic tank assembly .............................................................................................2079 Removal and installation of control valve assembly ..............................................................................................2082 Removal and installation of steering pump and power train pump assembly .........................................................................2085 Removal and installation of work equipment pump and cooling fan pump assembly ...................................................................2087 Disassembly and assembly of hydraulic cylinder assembly .........................................................................................2089 Work equipment ......................................................................................................................................2096 Removal and installation of work equipment assembly .............................................................................................2096 Cab and its attachments .............................................................................................................................2101 Removal and installation of operator's cab and floor frame assembly .............................................................................2101 Removal and installation of operator's cab glass (stuck window glass) ...........................................................................2105 Removal and installation of operator's seat assembly ............................................................................................2113 Removal and installation of seat belt ...........................................................................................................2115 Removal and installation of air conditioner unit assembly .......................................................................................2116 Removal and installation of air conditioner compressor assembly .................................................................................2121 Removal and installation of air conditioner condenser assembly ..................................................................................2123 Electrical system ...................................................................................................................................2125 Removal and installation of machine monitor assembly ............................................................................................2125 Removal and installation of engine controller assembly ..........................................................................................2126 Removal and installation of work equipment controller assembly ..................................................................................2127 Removal and installation of transmission controller assembly ....................................................................................2129 Removal and installation of monitor controller assembly .........................................................................................2130 Removal and installation of mass air flow and temperature sensor ................................................................................2132 Removal and installation of KOMTRAX terminal assembly ...........................................................................................2133 60 Maintenance standard .................................................................................................................................2135 Table of contents ...................................................................................................................................2136 Engine and cooling system ...........................................................................................................................2137 Engine related parts ............................................................................................................................2137 Cooling fan pump ................................................................................................................................2138 Cooling fan motor ...............................................................................................................................2141 Power train .........................................................................................................................................2143 Drive shaft .....................................................................................................................................2143 Torque converter ................................................................................................................................2144 Transmission ....................................................................................................................................2146 Transmission control valve ......................................................................................................................2155 Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV .....................................................................................2157 3rd, 4th clutch ECMV ............................................................................................................................2158 Lockup clutch ECMV ..............................................................................................................................2159 Main relief and torque converter relief valve ...................................................................................................2160 Axle ............................................................................................................................................2161 Differential ....................................................................................................................................2163 Final drive .....................................................................................................................................2173 Steering system .....................................................................................................................................2175 Steering column .................................................................................................................................2175 Steering pump ...................................................................................................................................2176 Steering valve ..................................................................................................................................2180 Steering cylinder ...............................................................................................................................2182 Emergency steering pump .........................................................................................................................2185 Brake system ........................................................................................................................................2186 Charge valve ....................................................................................................................................2186 Slack adjuster ..................................................................................................................................2188 Brake ...........................................................................................................................................2189 Parking brake ...................................................................................................................................2191 Parking brake solenoid valve ....................................................................................................................2192 Undercarriage and frame .............................................................................................................................2193 Axle mount and center hinge pin .................................................................................................................2193 Hydraulic system ....................................................................................................................................2197 Hydraulic tank ..................................................................................................................................2197 Double type gear pump ...........................................................................................................................2198 Work equipment pump .............................................................................................................................2199 Control valve ...................................................................................................................................2201 Work equipment ......................................................................................................................................2210 Work equipment linkage ..........................................................................................................................2210 Bucket ..........................................................................................................................................2214 Work equipment cylinder .........................................................................................................................2215 80 Appendix .............................................................................................................................................2217 Table of contents ...................................................................................................................................2218 Air conditioner components ..........................................................................................................................2219 Precautions for refrigerant .....................................................................................................................2219 Air conditioner component .......................................................................................................................2220 Configuration and function of refrigeration cycle ...............................................................................................2222 Outline of refrigeration cycle ..................................................................................................................2223 Air conditioner unit ............................................................................................................................2225 Dual pressure switch ............................................................................................................................2230 Air conditioner controller ......................................................................................................................2231 Compressor ......................................................................................................................................2232 Condenser .......................................................................................................................................2233 Receiver drier ..................................................................................................................................2234 Sunlight sensor .................................................................................................................................2236 Outer temperature sensor (outside air temperature sensor) .......................................................................................2237 Procedure for testing and troubleshooting .......................................................................................................2238 Circuit diagram and arrangement of connector pins ...............................................................................................2240 System diagram ..................................................................................................................................2243 Parts and connectors layout .....................................................................................................................2246 Testing with self-diagnosis function ............................................................................................................2251 How to open the electrical system abnormality record screen in service mode of the machine monitor ..............................................2252 Testing temperature control system ..............................................................................................................2254 Testing vent (mode) changeover ..................................................................................................................2256 Testing FRESH/RECIRC air changeover .............................................................................................................2258 Check evaporator temperature sensor .............................................................................................................2260 Testing relays ..................................................................................................................................2262 Troubleshooting chart 1 .........................................................................................................................2264 Troubleshooting chart 2 .........................................................................................................................2265 Information in troubleshooting table ............................................................................................................2267 Failure code list related to air conditioner ....................................................................................................2268 Failure code [879AKA] A/C Inner Sensor Open Circuit .............................................................................................2269 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................2271 Failure code [879BKA] A/C Outer Sensor Open Circuit .............................................................................................2273 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................2275 Failure code [879CKA] Ventilating Sensor Open Circuit ...........................................................................................2277 Failure code [879CKB] Ventilating Sensor Short Circuit ..........................................................................................2279 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .....................................................................................2281 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................2283 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................2286 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ............................................2289 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................................................2292 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..........................................................2295 A-4 Troubleshooting for FRESH/RECIRC air changeover .............................................................................................2298 Troubleshooting with gauge pressure .............................................................................................................2300 Connection of service tool ......................................................................................................................2303 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit .........................................................2305 Handling of compressor oil ......................................................................................................................2307 90 Diagrams and drawings ................................................................................................................................2309 Table of contents ...................................................................................................................................2310 Hydraulic circuit diagram ...........................................................................................................................2311 Symbols in hydraulic circuit diagram ............................................................................................................2311 Hydraulic circuit diagram of power train ........................................................................................................2315 Electric circuit diagram ............................................................................................................................2318 Symbols in electric circuit diagram .............................................................................................................2318
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