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KOMATSU WA470-7 WHEEL LOADER SHOP MANUAL VENBM42500 – PDF DOWNLOAD
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Description
KOMATSU WA470-7 WHEEL LOADER SHOP MANUAL VENBM42500 – PDF DOWNLOAD
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KOMATSU WA470-7 WHEEL LOADER SHOP MANUAL VENBM42500 – PDF DOWNLOAD
Language : English
Pages : 2361
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA470-7 WHEEL LOADER SHOP MANUAL VENBM42500 – PDF DOWNLOAD
00 Index and foreword ................................................................................................................................... 3 Index ............................................................................................................................................... 4 Foreword, safety and general information ............................................................................................................ 20 Important safety notice ......................................................................................................................... 20 How to read the shop manual ..................................................................................................................... 27 Explanation of terms for maintenance standard ................................................................................................... 29 Handling equipment of fuel system devices ....................................................................................................... 31 Handling of intake system parts ................................................................................................................. 32 Handling of hydraulic equipment ................................................................................................................. 33 Method of disconnecting and connecting of push-pull type coupler ................................................................................ 35 Handling of electrical equipment ................................................................................................................ 38 How to read electric wire code .................................................................................................................. 46 Precautions when performing operation ........................................................................................................... 49 Practical use of KOMTRAX ........................................................................................................................ 53 Standard tightening torque table ................................................................................................................ 54 List of abbreviation ............................................................................................................................ 58 Conversion table ................................................................................................................................ 63 01 Specification ........................................................................................................................................ 69 Table of contents ................................................................................................................................... 70 Specifications ...................................................................................................................................... 71 Specification drawing ........................................................................................................................... 71 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 Central lubrication system (CLS)..................................................................................................................... 461 Auto-grease pump................................................................................................................................. 461 Changing the lubrication interval times.......................................................................................................... 462 Operating the central lubrication system......................................................................................................... 463 Display and control unit......................................................................................................................... 464 LED-display...................................................................................................................................... 464 Push buttons..................................................................................................................................... 464 Three-digit LED display.......................................................................................................................... 465 Check central lubrication system, fill up grease................................................................................................. 466 20 Standard value tables ................................................................................................................................ 469 Table of contents ................................................................................................................................... 470 Standard service value table ........................................................................................................................ 471 Standard value table for engine ................................................................................................................. 471 Standard value table for machine ................................................................................................................ 473 Standard value table for electrical system ...................................................................................................... 486 30 Testing and adjusting ................................................................................................................................ 501 Table of contents ................................................................................................................................... 502 General information on testing and adjusting ........................................................................................................ 504 Tools for testing and adjusting ................................................................................................................. 504 Sketch of tools for testing and adjusting ....................................................................................................... 508 Engine and cooling system ........................................................................................................................... 510 Testing engine speed ............................................................................................................................ 510 Testing boost pressure .......................................................................................................................... 512 Testing exhaust gas color ....................................................................................................................... 514 Testing and adjusting valve clearance ........................................................................................................... 516 Testing compression pressure .................................................................................................................... 518 Testing blowby pressure ......................................................................................................................... 522 Testing engine oil pressure ..................................................................................................................... 524 Testing EGR valve and KVGT oil pressures ........................................................................................................ 525 Testing fuel pressure ........................................................................................................................... 526 Testing fuel return rate and leakage ............................................................................................................ 527 Bleeding air from fuel system ................................................................................................................... 531 Testing fuel circuit for leakage ................................................................................................................ 533 Handling cylinder cutout mode operation ......................................................................................................... 534 Handling no injection cranking operation ........................................................................................................ 535 Testing of KDPF and muffler stack for looseness and damage ...................................................................................... 536 Testing of installed condition of cylinder head and manifolds ................................................................................... 537 Testing engine piping for damage and looseness .................................................................................................. 538 Testing and adjusting air conditioner compressor belt tension ................................................................................... 539 Testing and adjusting alternator belt tension ................................................................................................... 541 Procedures for cleaning fuel doser .............................................................................................................. 543 Writing compensation values at replacement of injector and engine controller .................................................................... 546 Power train ......................................................................................................................................... 550 Adjusting transmission output speed sensor ...................................................................................................... 550 Adjusting transmission input speed sensor ....................................................................................................... 551 Flushing procedure for torque converter and transmission hydraulic circuit ...................................................................... 552 Retrieval of disabled machine due to transmission valve failure ................................................................................. 554 Testing oil leakage from axle final drive ....................................................................................................... 556 Testing drive shaft for looseness, backlash, and damage ......................................................................................... 557 Testing and adjusting power train oil pressure .................................................................................................. 558 Steering system ..................................................................................................................................... 573 Testing directional lever ....................................................................................................................... 573 Testing steering wheel .......................................................................................................................... 574 Testing work equipment control lever ............................................................................................................ 576 Testing and adjusting steering circuit oil pressure ............................................................................................. 578 Bleeding air from steering cylinder circuit. .................................................................................................... 581 Testing and adjusting steering stopper valve .................................................................................................... 582 Brake system ........................................................................................................................................ 583 Testing brake pedal ............................................................................................................................. 583 Testing and adjusting brake pedal linkage ....................................................................................................... 584 Testing braking performance ..................................................................................................................... 585 Testing and adjusting of accumulator charge pressure ............................................................................................ 586 Testing of brake accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas ............................... 588 Testing wheel brake oil pressure ................................................................................................................ 592 Testing lowering of wheel brake pressure ........................................................................................................ 594 Testing wear of wheel brake disc ................................................................................................................ 596 Bleeding air from wheel brake circuit ........................................................................................................... 597 Releasing remaining pressure in brake accumulator circuit ....................................................................................... 599 Testing parking brake performance ............................................................................................................... 600 Testing parking brake oil pressure .............................................................................................................. 601 Testing wear of parking brake disc .............................................................................................................. 602 Method of releasing parking brake manually ...................................................................................................... 603 Hydraulic system .................................................................................................................................... 605 Testing fan speed ............................................................................................................................... 605 Testing fan pump circuit oil pressure ........................................................................................................... 606 Bleeding air from hydraulic fan circuit ......................................................................................................... 608 Testing and adjusting work equipment EPC oil pressure ........................................................................................... 610 Testing and adjusting work equipment oil pressure ............................................................................................... 613 Bleeding air from work equipment circuit ........................................................................................................ 617 Releasing remaining pressure from work equipment circuit ........................................................................................ 618 Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ...................................... 619 Work equipment ...................................................................................................................................... 623 Testing and adjusting bucket position detection lever ........................................................................................... 623 Testing and adjusting boom position detection lever ............................................................................................. 624 Electrical system ................................................................................................................................... 625 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor .......................................................... 625 Special functions of machine monitor ............................................................................................................ 627 Adjusting rearview camera angle ................................................................................................................. 716 Handling voltage circuit of engine controller ................................................................................................... 717 Handling battery disconnect switch .............................................................................................................. 718 Testing diodes .................................................................................................................................. 719 Pm clinic ........................................................................................................................................... 720 Pm Clinic service ............................................................................................................................... 720 Check sheet ..................................................................................................................................... 721 40 Troubleshooting ...................................................................................................................................... 727 Table of contents ................................................................................................................................... 728 General information on troubleshooting .............................................................................................................. 737 Troubleshooting points .......................................................................................................................... 737 Sequence of events in troubleshooting ........................................................................................................... 739 Check before troubleshooting .................................................................................................................... 741 Inspection procedure before troubleshooting ..................................................................................................... 743 Preparation work for troubleshooting of electrical system ....................................................................................... 760 Classification and procedures for troubleshooting ............................................................................................... 766 Symptom and troubleshooting numbers ............................................................................................................. 769 Information in troubleshooting table ............................................................................................................ 772 Connector list and layout ....................................................................................................................... 774 Connector contact identification ................................................................................................................ 788 T-branch box and T-branch adapter table ......................................................................................................... 824 Fuse location table ............................................................................................................................. 830 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................................................................... 833 Precautions on troubleshooting of machine monitor ............................................................................................... 836 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ......................................................... 838 Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................................. 843 Fabrication of short-circuit connector (for CA1883 and CA3135) .................................................................................. 844 Failure codes table ............................................................................................................................. 845 Troubleshooting by failure code (Display of code) ................................................................................................... 859 Failure code [1500L0] Double Engagement of T/M Clutches ......................................................................................... 859 Failure code [15SAL1] Release Trouble of ECMV (Forward) ......................................................................................... 860 Failure code [15SALH] Malfunction of ECMV (Forward) ............................................................................................. 862 Failure code [15SBL1] Release Trouble of ECMV (Reverse) ......................................................................................... 864 Failure code [15SBLH] Malfunction of ECMV (Reverse) ............................................................................................. 866 Failure code [15SEL1] Release Trouble of ECMV (1st) ............................................................................................. 868 Failure code [15SELH] Malfunction of ECMV (1st) ................................................................................................. 870 Failure code [15SFL1] Release Trouble of ECMV (2nd) ............................................................................................. 872 Failure code [15SFLH] Malfunction of ECMV (2nd) ................................................................................................. 874 Failure code [15SGL1] Release Trouble of ECMV (3rd) ............................................................................................. 876 Failure code [15SGLH] Malfunction of ECMV (3rd) ................................................................................................. 878 Failure code [15SHL1] Release Trouble of ECMV (4th) ............................................................................................. 880 Failure code [15SHLH] Malfunction of ECMV (4th) ................................................................................................. 882 Failure code [2F00MA] Failure of Parking Brake Circuit .......................................................................................... 884 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...................................................................................... 888 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....................................................................................... 890 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................................. 892 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................ 893 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................................. 894 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................ 895 Failure code [879CKA] Ventilating Sensor Open Circuit ........................................................................................... 896 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................................................... 897 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..................................................................................... 898 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................ 899 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................ 900 Failure code [989A00] Engine Overrun Prevention Activated ....................................................................................... 901 Failure code [989L00] Engine Controller Lock Caution 1 .......................................................................................... 902 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................................... 903 Failure code [989N00] Engine Controller Lock Caution 3 .......................................................................................... 904 Failure code [A1U0N3] HC Desorb Request 1 ....................................................................................................... 905 Failure code [A1U0N4] HC Desorb Request 2 ....................................................................................................... 907 Failure code [AA10NX] Air Cleaner Clogging ...................................................................................................... 909 Failure code [B@BAZG] Eng Oil Press Low ......................................................................................................... 911 Failure code [B@BAZK] Eng Oil Level Low ......................................................................................................... 912 Failure code [B@BCNS] Eng Water Overheat ........................................................................................................ 914 Failure code [B@BCZK] Eng Water Level Low ....................................................................................................... 915 Failure code [B@CENS] T/C Oil Temp. Overheat .................................................................................................... 917 Failure code [B@HANS] HYD Oil Temp. Overheat .................................................................................................... 918 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................................... 919 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................................ 920 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................................. 922 Failure code [CA131] Throttle Sensor High Error ................................................................................................. 924 Failure code [CA132] Throttle Sensor Low Error .................................................................................................. 926 Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................................ 928 Failure code [CA141] Eng Oil Press Sensor Low Error ............................................................................................. 930 Failure code [CA144] Coolant Temp Sens High Error ............................................................................................... 932 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................................ 934 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................................. 936 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................................. 938 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................................. 940 Failure code [CA221] Ambient Press Sensor High Error ............................................................................................ 942 Failure code [CA222] Ambient Press Sensor Low Error ............................................................................................. 944 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................................ 946 Failure code [CA234] Eng Overspeed .............................................................................................................. 947 Failure code [CA238] Ne Speed Sensor Supply Volt Error .......................................................................................... 948 Failure code [CA239] Ne Speed Sens Supply Volt High Error ....................................................................................... 949 Failure code [CA271] IMV/PCV1 Short Error ....................................................................................................... 950 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................................ 951 Failure code [CA273] PCV2 Short Error ........................................................................................................... 952 Failure code [CA274] PCV2 Open Error ............................................................................................................ 953 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................................................... 954 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................................................... 956 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................................................... 958 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................................................... 960 Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................................................... 962 Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................................................... 964 Failure code [CA343] ECM Critical Internal Failure .............................................................................................. 966 Failure code [CA351] Injectors Drive Circuit Error .............................................................................................. 967 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................................. 968 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................................ 970 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................................. 972 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................................ 974 Failure code [CA431] Idle Validation Sw Error ................................................................................................... 975 Failure code [CA432] Idle Validation Process Error .............................................................................................. 978 Failure code [CA441] Battery Voltage Low Error .................................................................................................. 981 Failure code [CA442] Battery Voltage High Error ................................................................................................. 983 Failure code [CA449] Rail Press Very High Error ................................................................................................. 984 Failure code [CA451] Rail Press Sensor High Error ............................................................................................... 985 Failure code [CA452] Rail Press Sensor Low Error ................................................................................................ 987 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................................ 989 Failure code [CA516] Rail Press Sens Sup Volt Low Error ......................................................................................... 991 Failure code [CA553] Rail Press High Error ...................................................................................................... 993 Failure code [CA555] Crankcase Press High Error 1 ............................................................................................... 994 Failure code [CA556] Crankcase Press High Error 2 ............................................................................................... 995 Failure code [CA559] Rail Press Low Error ....................................................................................................... 996 Failure code [CA595] Turbo Speed High Error 2 ...................................................................................................1000 Failure code [CA687] Turbo Speed Low Error ......................................................................................................1001 Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................................................1003 Failure code [CA691] Intake Air Temp Sens High Error ............................................................................................1005 Failure code [CA692] Intake Air Temp Sens Low Error .............................................................................................1007 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................................1009 Failure code [CA698] ECM Int Temp Sensor Low Error ..............................................................................................1010 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................................1011 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................................1012 Failure code [CA1117] Persistent Data Lost Error ................................................................................................1014 Failure code [CA1664] KDOC Malfunction ..........................................................................................................1015 Failure code [CA1691] Regeneration Ineffective ..................................................................................................1018 Failure code [CA1695] Sensor 5 Supply Volt High Error ...........................................................................................1021 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................................................1022 Failure code [CA1843] Crankcase Press Sens High Error ...........................................................................................1024 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................................................1026 Failure code [CA1879] KDPF Delta P Sensor High Error ............................................................................................1028 Failure code [CA1881] KDPF Delta P Sensor Low Error .............................................................................................1030 Failure code [CA1883] KDPF Delta P Sens In Range Error ..........................................................................................1032 Failure code [CA1921] KDPF Soot Load High Error 1 ...............................................................................................1035 Failure code [CA1922] KDPF Soot Load High Error 2 ...............................................................................................1038 Failure code [CA1923] Dosing Fuel Valve 1 High Error ............................................................................................1043 Failure code [CA1924] Dosing Fuel Valve 1 Low Error .............................................................................................1045 Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ........................................................................................1048 Failure code [CA1927] Dosing Fuel Press Sens High Error .........................................................................................1050 Failure code [CA1928] Dosing Fuel Press Sens Low Error ..........................................................................................1052 Failure code [CA1942] Crankcase Press Sens In Range Error .......................................................................................1054 Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...........................................................................................1055 Failure code [CA1977] Fuel Doser Open/Short Error ...............................................................................................1057 Failure code [CA1993] KDPF Delta Pressure Low Error .............................................................................................1059 Failure code [CA2185] Throt Sensor Sup Volt High Error ..........................................................................................1061 Failure code [CA2186] Throt Sensor Sup Volt Low Error ...........................................................................................1063 Failure code [CA2249] Rail Press Very Low Error .................................................................................................1065 Failure code [CA2265] Fuel Feed Pump Open Error .................................................................................................1066 Failure code [CA2266] Fuel Feed Pump Short Error ................................................................................................1068 Failure code [CA2271] EGR Valve Pos Sens High Error .............................................................................................1070 Failure code [CA2272] EGR Valve Pos Sens Low Error ..............................................................................................1072 Failure code [CA2349] EGR Valve Solenoid Open Error .............................................................................................1074 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................................1076 Failure code [CA2357] EGR Valve Servo Error .....................................................................................................1078 Failure code [CA2381] KVGT Pos Sens High Error ..................................................................................................1079 Failure code [CA2382] KVGT Pos Sens Low Error ...................................................................................................1081 Failure code [CA2383] KVGT Solenoid Open Error ..................................................................................................1083 Failure code [CA2386] KVGT Solenoid Short Error .................................................................................................1085 Failure code [CA2387] KVGT Servo Error ..........................................................................................................1087 Failure code [CA2555] Grid Htr Relay Volt Low Error .............................................................................................1088 Failure code [CA2556] Grid Htr Relay Volt High Error ............................................................................................1090 Failure code [CA2637] KDOC Face Plugging ........................................................................................................1092 Failure code [CA2639] Manual Stationary Regeneration Request ....................................................................................1094 Failure code [CA2732] Dosing Fuel Valve 2 High Error ............................................................................................1097 Failure code [CA2733] Dosing Fuel Valve 2 Low Error .............................................................................................1099 Failure code [CA2741] Dosing Fuel Valve Swap Error ..............................................................................................1101 Failure code [CA2765] Inj Trim Data Error .......................................................................................................1103 Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...........................................................................................1104 Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ..........................................................................................1107 Failure code [CA3133] KDPF Outlet Press Sens High Error .........................................................................................1112 Failure code [CA3134] KDPF Outlet Press Sens Low Error ..........................................................................................1114 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .....................................................................................1116 Failure code [CA3167] Fuel Doser Degradation ....................................................................................................1119 Failure code [CA3251] KDOC Inlet Temp High Error ................................................................................................1122 Failure code [CA3253] KDOC Temp Error - Non Regeneration ........................................................................................1125 Failure code [CA3254] KDOC Outlet Temp High Error 1 .............................................................................................1128 Failure code [CA3255] KDPF Temp Error - Non Regeneration ........................................................................................1131 Failure code [CA3256] KDPF Outlet Temp High Error 1 .............................................................................................1135 Failure code [CA3311] KDOC Outlet Temp High Error 2 .............................................................................................1138 Failure code [CA3312] KDPF Outlet Temp High Error 2 .............................................................................................1141 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ..........................................................................................1144 Failure code [CA3314] KDOC Inlet Temp Sens High Error ...........................................................................................1147 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .......................................................................................1151 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...........................................................................................1156 Failure code [CA3317] KDOC Outlet Temp Sens High Error ..........................................................................................1159 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ......................................................................................1163 Failure code [CA3319] KDPF Outlet Temp Sens High Error ..........................................................................................1168 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...........................................................................................1172 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ......................................................................................1175 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ..................................................................................1180 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...................................................................................1182 Failure code [D150KA] Disconnection of Emerg. Steering Relay ....................................................................................1184 Failure code [D150KB] Ground Fault of Emerg. Steering Relay .....................................................................................1186 Failure code [D150KY] Hot Short of Emergency Steering Relay .....................................................................................1188 Failure code [D160KA] Disconnection of Backup Lamp Relay Output .................................................................................1190 Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ..................................................................................1192 Failure code [D160KY] Hot Short of Backup Lamp Relay Output .....................................................................................1194 Failure code [D191KA] Disconnection of Neutral Output Relay .....................................................................................1196 Failure code [D191KB] Ground Fault of Neutral Output Relay ......................................................................................1198 Failure code [D191KY] Hot Short of Neutral Output Relay .........................................................................................1200 Failure code [D192KA] Disconnection of ECSS Solenoid ............................................................................................1202 Failure code [D192KB] Ground Fault of ECSS Solenoid .............................................................................................1204 Failure code [D192KY] Hot Short of ECSS Solenoid ................................................................................................1205 Failure code [D19JKZ] Personal Code Relay Abnormality ...........................................................................................1206 Failure code [D1E6KA] Disconnection of Parking Brake Relay ......................................................................................1208 Failure code [D1E6KB] Ground Fault of Parking Brake Relay .......................................................................................1210 Failure code [D1E6KY] Hot Short of Parking Brake Relay ..........................................................................................1212 Failure code [D5ZHKA] Failure of Key SW C Signal ................................................................................................1214 Failure code [D5ZHKB] Key SW C Signal Short Circuit .............................................................................................1216 Failure code [D5ZHKZ] Failure of Key SW C Signal ................................................................................................1218 Failure code [D5ZHL6] Disconnection of Key SW C .................................................................................................1220 Failure code [D811MC] KOMTRAX Error .............................................................................................................1222 Failure code [D862KA] GPS Antenna Open Circuit ..................................................................................................1223 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .....................................................................................1224 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ....................................................................................1226 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...................................................................................................1228 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .....................................................................................................1229 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................................................................1231 Failure code [DAF0MB] Monitor ROM Abnormality ...................................................................................................1232 Failure code [DAF0MC] Monitor Error .............................................................................................................1233 Failure code [DAF3KK] Controller Power Source Low (MON) .........................................................................................1234 Failure code [DAF8KB] Camera Power Supply Short Circuit .........................................................................................1236 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ....................................................................................1237 Failure code [DAFGMC] GPS Module Error ..........................................................................................................1239 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) .........................................................................................1240 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ........................................................................................1242 Failure code [DAFQKR] CAN2 Discon (Monitor) .....................................................................................................1244 Failure code [DAQ0KK] Controller Power Source Low (T/M) .........................................................................................1245 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ..................................................................................1248 Failure code [DAQ0MC] T/M Con Error .............................................................................................................1249 Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .........................................................................................1250 Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ...........................................................................................1252 Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ...................................................................................1255 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ....................................................................................1257 Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) .........................................................................................1258 Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ........................................................................................1260 Failure code [DAQQKR] CAN2 Discon (Transmission Con) ............................................................................................1262 Failure code [DAQRKR] CAN1 Discon (Transmission Con) ............................................................................................1263 Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ...................................................................................1264 Failure code [DAZ9KQ] A/C Model Selection Abnormality ...........................................................................................1265 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ..................................................................................................1266 Failure code [DB2QKR] CAN2 Discon (Engine Con) ..................................................................................................1267 Failure code [DB2RKR] CAN1 Discon (Engine Con) ..................................................................................................1272 Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................................................................1277 Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ..................................................................................1279 Failure code [DB90MC] BBC Error .................................................................................................................1280 Failure code [DB91KA] Disconnection of Key SW ACC (BBC) .........................................................................................1281 Failure code [DB92KK] Solenoid Power Source Low (BBC) ...........................................................................................1283 Failure code [DB95KX] Failure of 5 V Power Source 1 .............................................................................................1285 Failure code [DB96KX] Failure of 5 V Power Source 2 .............................................................................................1287 Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ....................................................................................1289 Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) .........................................................................................1290 Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ........................................................................................1292 Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .............................................................................................1294 Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .............................................................................................1295 Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ...................................................................................1296 Failure code [DBE5KX] Failure of 5V Power Source ................................................................................................1297 Failure code [DBE6KX] Failure of 24 V Power Source ..............................................................................................1299 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................................................................1301 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................................................................1303 Failure code [DDB6L4] Neutral Signal Malfunction ................................................................................................1305 Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ...................................................................................1308 Failure code [DDK3KA] FNR SW Input Signal Disconnection .........................................................................................1310 Failure code [DDK3KB] FNR SW Input Signal Short Circuit .........................................................................................1313 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ......................................................................................1315 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ......................................................................................1318 Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................................................................1320 Failure code [DDT0L4] Failure of Shift Mode Select SW ...........................................................................................1322 Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal .................................................................................1324 Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal .....................................................................................1326 Failure code [DDW9LD] Ground Fault of Kickdown Switch ...........................................................................................1328 Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW .........................................................................................1330 Failure code [DF10KA] Disconnection of Shift Lever Input ........................................................................................1332 Failure code [DF10KB] Ground Fault of Shift Lever Input .........................................................................................1334 Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor .....................................................................................1337 Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ......................................................................................1339 Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ......................................................................................1341 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ....................................................................................1343 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .........................................................................................1344 Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor .....................................................................................1346 Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ......................................................................................1349 Failure code [DH21KA] Failure of Loader Pump Press. Sensor ......................................................................................1351 Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ...................................................................................1353 Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit .....................................................................................1355 Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor .................................................................................1357 Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ...................................................................................1359 Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor .................................................................................1361 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .................................................................................1363 Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ................................................................................1365 Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ....................................................................................1367 Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit .................................................................................1369 Failure code [DHT8ZG] Steering Oil Pressure Low .................................................................................................1371 Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ...................................................................................1372 Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ....................................................................................1374 Failure code [DJF1KA] Disconnection of Fuel Level Sensor ........................................................................................1376 Failure code [DK55KA] Failure of FNR Lever Potentio .............................................................................................1378 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...................................................................................1381 Failure code [DK55L5] Failure of FNR Lever Potentio .............................................................................................1383 Failure code [DK59KA] Failure of Boom Lever Potentio (Main) .....................................................................................1384 Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ...................................................................................1387 Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................................................................1390 Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ......................................................................................1394 Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ....................................................................................1397 Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ...................................................................................1400 Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) .................................................................................1403 Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................................................................1406 Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ....................................................................................1410 Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ..................................................................................1413 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ......................................................................................1416 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ....................................................................................1419 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ..................................................................................1421 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) .......................................................................................1424 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) .....................................................................................1427 Failure code [DKA0KA] Failure of Boom Angle Sensor ..............................................................................................1429 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ....................................................................................1431 Failure code [DKA0L0] Boom Angle Sensor Dislocation .............................................................................................1433 Failure code [DKA1KA] Failure of Bucket Angle Sensor ............................................................................................1435 Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ..................................................................................1437 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ...................................................................................1439 Failure code [DLF1LC] Failure of T/M Input Speed Sensor .........................................................................................1441 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ................................................................................1443 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ......................................................................................1445 Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ................................................................................1447 Failure code [DLT3LC] Failure of Output Speed Sensor (Main) .....................................................................................1449 Failure code [DPQ1KR] LIN Discon (Switch Panel) .................................................................................................1451 Failure code [DPQ2KR] LIN Discon (LED Unit) .....................................................................................................1454 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ............................................................................................1457 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ..................................................................................................1460 Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .....................................................................................1462 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...................................................................................1464 Failure code [DV00KB] Ground Fault of Buzzer Output .............................................................................................1466 Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................................................................1468 Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) .................................................................................1470 Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................................................................1472 Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ................................................................................1474 Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) .................................................................................1476 Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ....................................................................................1478 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...................................................................................1480 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ................................................................................1482 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...................................................................................1484 Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ...................................................................................1486 Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................................................................1488 Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ...................................................................................1490 Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid .....................................................................................1492 Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ....................................................................................1494 Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. .......................................................................................1496 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ....................................................................................1497 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid .....................................................................................1499 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ........................................................................................1501 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................................................................1503 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ....................................................................................1505 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) .......................................................................................1507 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) .................................................................................1509 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ..................................................................................1511 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) .....................................................................................1513 Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ...................................................................................1515 Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................................................................1517 Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ...................................................................................1519 Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid .................................................................................1521 Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ..................................................................................1523 Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid .....................................................................................1525 Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...................................................................................1527 Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ................................................................................1529 Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid ...................................................................................1531 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ...................................................................................1532 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................................................................1534 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .......................................................................................1536 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ......................................................................................1538 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) .......................................................................................1540 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ..........................................................................................1542 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ......................................................................................1544 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .......................................................................................1546 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ..........................................................................................1548 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ......................................................................................1550 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) .......................................................................................1552 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ..........................................................................................1554 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ..................................................................................1556 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ...................................................................................1558 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ......................................................................................1560 Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ..................................................................................1562 Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ...................................................................................1564 Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ......................................................................................1566 Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ......................................................................................1568 Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) .......................................................................................1570 Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ..........................................................................................1572 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...................................................................................1574 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ....................................................................................1576 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .......................................................................................1578 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................................................................1580 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ....................................................................................1582 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) .......................................................................................1584 Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor ....................................................................................1586 Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor ....................................................................................1589 Failure code [DY30ME] Emerg. Steering Long-Time Activated .......................................................................................1593 Failure code [LA00L3] Failure of Fan Reverse ....................................................................................................1595 Troubleshooting of electrical system (E-mode) .......................................................................................................1596 E-1 Engine does not start .......................................................................................................................1596 E-2 Manual preheating system does not work ......................................................................................................1602 E-3 Automatic preheating system does not work ...................................................................................................1605 E-4 While preheating is working, preheating monitor does not light up ...........................................................................1607 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ................................................................1609 E-6 LCD unit on machine monitor displays nothing ................................................................................................1612 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) .......................................................1614 E-8 LCD on machine monitor does not display properly ............................................................................................1616 E-9 Meter unit display on machine monitor is abnormal ...........................................................................................1618 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...........................................................................1621 E-11 Caution LED on machine monitor is abnormal .................................................................................................1624 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...................................................1626 E-13 Two switches operation of switch panel on machine monitor does not function ................................................................1628 E-14 Switch panel buzzer of machine monitor is abnormal .........................................................................................1631 E-15 Rear view monitor does not light up or backlight flickers ..................................................................................1633 E-16 Rear view monitor images are not displayed clearly .........................................................................................1636 E-17 Rear view monitor brightness cannot be adjusted ............................................................................................1639 E-18 Night lighting lamp of rear view monitor is abnormal .......................................................................................1642 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly .......................................................1644 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position .........................................1645 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ..............................................1649 E-22 Air cleaner clogging indicator lamp does not light .........................................................................................1651 E-23 Radiator coolant level caution lamp does not light .........................................................................................1652 E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ..................1654 E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ....1656 E-26 Fuel level gauge does not indicate correct level ...........................................................................................1657 E-27 Seat belt caution lamp indication is abnormal ..............................................................................................1659 E-28 Horn does not sound ........................................................................................................................1660 E-29 Horn does not stop sounding ................................................................................................................1663 E-30 Alarm buzzer does not sound ................................................................................................................1665 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................................................................1666 E-32 Kickdown does not work when kickdown switch is turned ON ...................................................................................1667 E-33 The hold switch does not work when it is pressed ...........................................................................................1669 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 ..............1671 E-35 Transmission cut-off mode is not selected or not released ..................................................................................1674 E-36 Transmission cut-off setting cannot be released ............................................................................................1676 E-37 Directional selector (FNR) switch mode is not selected or not released .....................................................................1678 E-38 When operating engine power selection switch, engine power selection function does not operate properly ....................................1680 E-39 Flow of loader pump does not increase from the minimum rate ................................................................................1682 E-40 ECSS function cannot be selected or cannot be released .....................................................................................1683 E-41 None of headlamp, clearance lamp, and tail lamp lights .....................................................................................1685 E-42 Clearance lamp and tail lamp do not light up or go out .....................................................................................1687 E-43 Both High and Low beams of headlamp do not light up or go out ..............................................................................1690 E-44 Low beam of headlamp does not light up or go out ...........................................................................................1694 E-45 High beam of headlamp does not light up or go out ..........................................................................................1696 E-46 Front working lamp does not light up or go out .............................................................................................1698 E-47 Rear working lamp does not light up or go out ..............................................................................................1701 E-48 All of turn signal lamps and hazard lamps do not light up or go out ........................................................................1704 E-49 Turn signal lamps do not light up or go out ................................................................................................1707 E-50 Hazard lamp does not light up or go out ....................................................................................................1710 E-51 Brake lamp does not light or stays lighted .................................................................................................1713 E-52 Backup lamp does not light up or does not go out ...........................................................................................1716 E-53 Backup buzzer does not sound or continues to sound .........................................................................................1719 E-54 Front wiper does not operate ...............................................................................................................1721 E-55 Rear wiper does not operate ................................................................................................................1724 E-56 Window washer does not operate .............................................................................................................1726 E-57 Fuel feed pump does not operate or stop automatically ......................................................................................1729 E-58 KOMTRAX system does not operate properly ...................................................................................................1731 Troubleshooting of hydraulic and mechanical system (H-mode) .........................................................................................1733 Information described in troubleshooting table (H-mode) .........................................................................................1733 System chart of hydraulic and mechanical systems ................................................................................................1734 Failure mode and cause table ....................................................................................................................1737 H-1 Machine does not move off ...................................................................................................................1745 H-2 Torque converter lockup clutch is not disengaged (engine stalls) ............................................................................1748 H-3 Torque converter lockup clutch is not engaged ...............................................................................................1749 H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift .........................................1750 H-5 Large shock is made when machine starts or gear is shifted ..................................................................................1753 H-6 Machine starts or gear speed shifts with long time lag ......................................................................................1755 H-7 Torque converter oil temperature is high ....................................................................................................1757 H-8 Machine does not turn .......................................................................................................................1759 H-9 Turning response is poor ....................................................................................................................1761 H-10 Steering wheel is heavy to turn ............................................................................................................1763 H-11 Machine sways or large shocks are made while machine turns .................................................................................1764 H-12 Turning radius differs between right and left turns ........................................................................................1766 H-13 Wheel brakes do not work or are weak .......................................................................................................1767 H-14 Wheel brakes are not released or drag ......................................................................................................1769 H-15 Parking brake does not work or it is weak ..................................................................................................1770 H-16 Parking brake is not released or drags (including emergency release system) ................................................................1771 H-17 Boom does not rise .........................................................................................................................1772 H-18 Boom moves slow or boom lacks lifting force ................................................................................................1774 H-19 Rising boom slows down at certain height ...................................................................................................1776 H-20 Lift cylinders do not serve to hold bucket on ground .......................................................................................1777 H-21 Hydraulic drift of boom is large ...........................................................................................................1778 H-22 Boom moves up and down during operation ....................................................................................................1779 H-23 Bucket does not tilt back ..................................................................................................................1780 H-24 Bucket moves slow or lacks tilt-back force .................................................................................................1782 H-25 Bucket decelerates during tilt-back operation ..............................................................................................1784 H-26 Bucket cylinder does not hold bucket on ground .............................................................................................1785 H-27 Hydraulic drift of bucket is large .........................................................................................................1786 H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ............................................................1787 H-29 Boom and bucket control levers do not move smoothly and are heavy to move ..................................................................1788 H-30 Operating work equipment causes engine speed to lower significantly or engine to stall .....................................................1789 H-31 Large shocks are made when work equipment starts to move and stops .........................................................................1790 H-32 When certain work equipment stalls hydraulically, other work equipment moves ...............................................................1792 H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces .....................................................................1793 H-34 Bucket does not stop at the position which is set with remote bucket positioner ............................................................1794 H-35 Fan speed is abnormal (too high or low, or fan does not rotate) ............................................................................1795 H-36 Unusual noise is heard from around fan .....................................................................................................1796 Troubleshooting of engine (S-mode) ..................................................................................................................1797 Information mentioned in troubleshooting table (S mode) .........................................................................................1797 S-1 When starting switch is turned to START position, engine is not cranked .....................................................................1798 S-2 The engine cranks but exhaust smoke does not come out .......................................................................................1799 S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ......................................1800 S-4 Engine startability is poor .................................................................................................................1801 S-5 Engine does not pick-up smoothly ............................................................................................................1803 S-6 Engine stops during operation ...............................................................................................................1805 S-7 Engine runs rough or is unstable ............................................................................................................1807 S-8 Engine lacks power ..........................................................................................................................1808 S-9 KDPF gets clogged in a short time ...........................................................................................................1810 S-10 Engine oil consumption is excessive ........................................................................................................1812 S-11 Engine oil becomes contaminated early ......................................................................................................1813 S-12 Fuel consumption is excessive ..............................................................................................................1814 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...........................................................................1815 S-14 Oil pressure drops .........................................................................................................................1816 S-15 Fuel mixes into engine oil .................................................................................................................1817 S-16 Water mixes into engine oil (milky) ........................................................................................................1818 S-17 Coolant temperature rises too high (overheating) ...........................................................................................1819 S-18 Unusual noise is heard .....................................................................................................................1820 S-19 Vibration is excessive .....................................................................................................................1821 S-20 Air cannot be bled from fuel circuit .......................................................................................................1822 S-21 Active regeneration is executed frequently .................................................................................................1823 S-22 Active regeneration takes a long time ......................................................................................................1824 S-23 White smoke is exhausted during active regeneration ........................................................................................1825 Troubleshooting of Central Lubrication System (CLS)..................................................................................................1827 Trouble..........................................................................................................................................1827 Troubleshooting FPS..............................................................................................................................1828 Troubleshooting..................................................................................................................................1829 Pump Faults......................................................................................................................................1829 Pump faults......................................................................................................................................1830 Replace pump element.............................................................................................................................1831 Check power supply...............................................................................................................................1831 Changing the control unit:.......................................................................................................................1831 Troubleshooting – grease system faults...........................................................................................................1832 Venting of the system............................................................................................................................1833 General assembly advice..........................................................................................................................1834 50 Disassembly and assembly .............................................................................................................................1835 Table of contents ...................................................................................................................................1836 General information on disassembly and assembly .....................................................................................................1838 How to read this manual .........................................................................................................................1838 Coating materials list ..........................................................................................................................1840 Special tools list ..............................................................................................................................1844 Sketches of special tools .......................................................................................................................1851 Engine and cooling system ...........................................................................................................................1881 Removal and installation of supply pump assembly ................................................................................................1881 Removal and installation of injector assembly ...................................................................................................1887 Removal and installation of fuel doser assembly .................................................................................................1895 Removal and installation of cylinder head assembly ..............................................................................................1897 Removal and installation of engine hood assembly ................................................................................................1911 Removal and installation of grille assembly .....................................................................................................1913 Removal and installation of cooling system assembly .............................................................................................1916 Removal and installation of radiator core assembly ..............................................................................................1919 Removal and installation of aftercooler .........................................................................................................1921 Removal and installation of hydraulic oil cooler ................................................................................................1924 Removal and installation of power train oil cooler assembly .....................................................................................1926 Removal and installation of engine assembly .....................................................................................................1930 Removal and installation of engine front oil seal ...............................................................................................1936 Removal and installation of engine rear oil seal ................................................................................................1939 Removal and installation of cooling fan and cooling fan motor assembly ..........................................................................1944 Removal and installation of KDPF assembly .......................................................................................................1946 Disassembly and assembly of KDPF assembly .......................................................................................................1951 Removal and installation of KCCV assembly .......................................................................................................1960 Removal and installation of KVGT assembly .......................................................................................................1962 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ......................................................................1967 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .....................................................................1968 Removal and installation of air cleaner assembly ................................................................................................1970 Removal and installation of air conditioner compressor belt .....................................................................................1972 Removal and installation of alternator belt .....................................................................................................1973 Removal and installation of fuel tank assembly ..................................................................................................1974 Power train .........................................................................................................................................1977 Removal and installation of torque converter and transmission assembly ..........................................................................1977 Disassembly and assembly of transmission assembly ...............................................................................................1982 Disassembly and assembly of torque converter assembly ...........................................................................................2012 Disassembly and assembly of transmission clutch pack assembly ...................................................................................2019 Removal and installation of front axle assembly .................................................................................................2042 Removal and installation of rear axle assembly ..................................................................................................2044 Disassembly and assembly of axle housing assembly ...............................................................................................2049 Disassembly and assembly of differential assembly ...............................................................................................2059 Steering system .....................................................................................................................................2078 Removal and installation of steering valve assembly .............................................................................................2078 Brake system ........................................................................................................................................2080 Removal and installation of brake charge valve assembly .........................................................................................2080 Removal and installation of parking brake disc and plate ........................................................................................2081 Undercarriage and frame .............................................................................................................................2084 Removal and installation of center hinge pin ....................................................................................................2084 Removal and installation of counterweight assembly ..............................................................................................2092 Removal and installation of full-length fender assembly .........................................................................................2094 Hydraulic system ....................................................................................................................................2095 Removal and installation of hydraulic tank assembly .............................................................................................2095 Removal and installation of control valve assembly ..............................................................................................2098 Removal and installation of steering pump and power train pump assembly .........................................................................2101 Removal and installation of work equipment pump and cooling fan pump assembly ...................................................................2103 Disassembly and assembly of hydraulic cylinder assembly .........................................................................................2105 Work equipment ......................................................................................................................................2112 Removal and installation of work equipment assembly .............................................................................................2112 Cab and its attachments .............................................................................................................................2117 Removal and installation of operator's cab and floor frame assembly .............................................................................2117 Removal and installation of operator's cab glass (stuck window glass) ...........................................................................2121 Removal and installation of operator's seat assembly ............................................................................................2129 Removal and installation of seat belt ...........................................................................................................2131 Removal and installation of air conditioner unit assembly .......................................................................................2132 Removal and installation of air conditioner compressor assembly .................................................................................2137 Removal and installation of air conditioner condenser assembly ..................................................................................2139 Electrical system ...................................................................................................................................2141 Removal and installation of machine monitor assembly ............................................................................................2141 Removal and installation of engine controller assembly ..........................................................................................2142 Removal and installation of work equipment controller assembly ..................................................................................2143 Removal and installation of transmission controller assembly ....................................................................................2145 Removal and installation of monitor controller assembly .........................................................................................2146 Removal and installation of mass air flow and temperature sensor ................................................................................2148 Removal and installation of KOMTRAX terminal assembly ...........................................................................................2149 60 Maintenance standard .................................................................................................................................2151 Table of contents ...................................................................................................................................2152 Engine and cooling system ...........................................................................................................................2153 Engine related parts ............................................................................................................................2153 Cooling fan pump ................................................................................................................................2154 Cooling fan motor ...............................................................................................................................2157 Power train .........................................................................................................................................2159 Drive shaft .....................................................................................................................................2159 Torque converter ................................................................................................................................2160 Transmission ....................................................................................................................................2162 Transmission control valve ......................................................................................................................2171 Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV .....................................................................................2173 3rd, 4th clutch ECMV ............................................................................................................................2174 Lockup clutch ECMV ..............................................................................................................................2175 Main relief and torque converter relief valve ...................................................................................................2176 Axle ............................................................................................................................................2177 Differential ....................................................................................................................................2179 Final drive .....................................................................................................................................2189 Steering system .....................................................................................................................................2191 Steering column .................................................................................................................................2191 Steering pump ...................................................................................................................................2192 Steering valve ..................................................................................................................................2196 Steering cylinder ...............................................................................................................................2198 Emergency steering pump .........................................................................................................................2201 Brake system ........................................................................................................................................2202 Charge valve ....................................................................................................................................2202 Slack adjuster ..................................................................................................................................2204 Brake ...........................................................................................................................................2205 Parking brake ...................................................................................................................................2207 Parking brake solenoid valve ....................................................................................................................2208 Undercarriage and frame .............................................................................................................................2209 Axle mount and center hinge pin .................................................................................................................2209 Hydraulic system ....................................................................................................................................2213 Hydraulic tank ..................................................................................................................................2213 Double type gear pump ...........................................................................................................................2214 Work equipment pump .............................................................................................................................2215 Control valve ...................................................................................................................................2217 Work equipment ......................................................................................................................................2226 Work equipment linkage ..........................................................................................................................2226 Bucket ..........................................................................................................................................2230 Work equipment cylinder .........................................................................................................................2231 80 Appendix .............................................................................................................................................2233 Table of contents ...................................................................................................................................2234 Air conditioner components ..........................................................................................................................2235 Precautions for refrigerant .....................................................................................................................2235 Air conditioner component .......................................................................................................................2236 Configuration and function of refrigeration cycle ...............................................................................................2238 Outline of refrigeration cycle ..................................................................................................................2239 Air conditioner unit ............................................................................................................................2241 Dual pressure switch ............................................................................................................................2246 Air conditioner controller ......................................................................................................................2247 Compressor ......................................................................................................................................2248 Condenser .......................................................................................................................................2249 Receiver drier ..................................................................................................................................2250 Sunlight sensor .................................................................................................................................2252 Outer temperature sensor (outside air temperature sensor) .......................................................................................2253 Procedure for testing and troubleshooting .......................................................................................................2254 Circuit diagram and arrangement of connector pins ...............................................................................................2256 System diagram ..................................................................................................................................2259 Parts and connectors layout .....................................................................................................................2262 Testing with self-diagnosis function ............................................................................................................2267 How to open the electrical system abnormality record screen in service mode of the machine monitor ..............................................2268 Testing temperature control system ..............................................................................................................2270 Testing vent (mode) changeover ..................................................................................................................2272 Testing FRESH/RECIRC air changeover .............................................................................................................2274 Check evaporator temperature sensor .............................................................................................................2276 Testing relays ..................................................................................................................................2278 Troubleshooting chart 1 .........................................................................................................................2280 Troubleshooting chart 2 .........................................................................................................................2281 Information in troubleshooting table ............................................................................................................2283 Failure code list related to air conditioner ....................................................................................................2284 Failure code [879AKA] A/C Inner Sensor Open Circuit .............................................................................................2285 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................2287 Failure code [879BKA] A/C Outer Sensor Open Circuit .............................................................................................2289 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................2291 Failure code [879CKA] Ventilating Sensor Open Circuit ...........................................................................................2293 Failure code [879CKB] Ventilating Sensor Short Circuit ..........................................................................................2295 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .....................................................................................2297 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................2299 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................2302 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ............................................2305 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................................................2308 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..........................................................2311 A-4 Troubleshooting for FRESH/RECIRC air changeover .............................................................................................2314 Troubleshooting with gauge pressure .............................................................................................................2316 Connection of service tool ......................................................................................................................2319 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit .........................................................2321 Handling of compressor oil ......................................................................................................................2323 90 Diagrams and drawings ................................................................................................................................2325 Table of contents ...................................................................................................................................2326 Hydraulic circuit diagram ...........................................................................................................................2327 Symbols in hydraulic circuit diagram ............................................................................................................2327 Hydraulic circuit diagram of power train ........................................................................................................2331 Circuit diagram of Central Lubrication System (CLS)..............................................................................................2332 Hydraulic circuit diagram ....................................................................................................................... 0 Electric circuit diagram ............................................................................................................................2334 Symbols in electric circuit diagram .............................................................................................................2334 Electrical circuit diagram of machine body ...................................................................................................... 0 Electrical circuit diagram of floor ............................................................................................................. 0
DESCRIPTION:
KOMATSU WA470-7 WHEEL LOADER SHOP MANUAL VENBM42500 – PDF DOWNLOAD
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, forklift truck, service car, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 21/12/24
