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Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-03 – PDF DOWNLOAD
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Komatsu WA500-7 Wheel Loader Shop Manual
SERIAL NUMBERS : 10001 and up
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Description
Komatsu WA500-7 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA500-7 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA500-7
Serial Number: 10001 and up
Book Code: SEN05693-03
Language: English
Pages: 2520
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA500-7 Wheel Loader Shop Manual
How to read the shop manual:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu WA500-7 Wheel Loader Shop Manual
COVER.................................................................................................................................................... 1 00 Index and foreword ................................................................................................................................... 3 Index ............................................................................................................................................... 4 Foreword, safety and general information ............................................................................................................ 21 Important safety notice ......................................................................................................................... 21 How to read the shop manual ..................................................................................................................... 28 Explanation of terms for maintenance standard ................................................................................................... 30 Handling equipment of fuel system devices ....................................................................................................... 32 Handling of intake system parts ................................................................................................................. 33 Handling of hydraulic equipment ................................................................................................................. 34 Method of disconnecting and connecting of push-pull type coupler ................................................................................ 36 Handling of electrical equipment ................................................................................................................ 39 How to read electric wire code .................................................................................................................. 47 Precautions when performing operation ........................................................................................................... 50 Practical use of KOMTRAX ........................................................................................................................ 54 Standard tightening torque table ................................................................................................................ 55 List of abbreviation ............................................................................................................................ 59 Conversion table ................................................................................................................................ 64 01 Specification ........................................................................................................................................ 69 Table of contents ................................................................................................................................... 70 Specifications ...................................................................................................................................... 71 Specification drawing ........................................................................................................................... 71 Specification ................................................................................................................................... 73 Weight table .................................................................................................................................... 80 Table of fuel, coolant, and lubricants .......................................................................................................... 82 10 Structure and function ............................................................................................................................... 85 Table of contents ................................................................................................................................... 86 Engine and cooling system ........................................................................................................................... 88 Engine related parts ............................................................................................................................ 88 KVGT ............................................................................................................................................ 90 EGR system piping drawing ....................................................................................................................... 96 EGR system circuit diagram ...................................................................................................................... 98 EGR valve ....................................................................................................................................... 99 EGR cooler ...................................................................................................................................... 101 KCCV layout drawing ............................................................................................................................. 103 KCCV ventilator ................................................................................................................................. 105 KDPF ............................................................................................................................................ 107 Engine mount and transmission mount ............................................................................................................. 111 Joint ........................................................................................................................................... 112 Cooling system .................................................................................................................................. 113 Cooling fan pump ................................................................................................................................ 117 Cooling fan motor ............................................................................................................................... 126 Power train ......................................................................................................................................... 133 Power train system .............................................................................................................................. 133 Drive shaft ..................................................................................................................................... 136 Power train piping drawing ...................................................................................................................... 137 Transmission control ............................................................................................................................ 138 Torque converter ................................................................................................................................ 140 Torque converter regulator valve ................................................................................................................ 147 Transmission .................................................................................................................................... 149 Transfer ........................................................................................................................................ 166 Transmission control valve ...................................................................................................................... 168 Forward and reverse clutch ECMV and gear speed clutch ECMV ...................................................................................... 171 Lockup clutch ECMV .............................................................................................................................. 178 Main relief valve, torque converter relief valve, and main flow selector valve .................................................................. 182 Torque converter oil cooler ..................................................................................................................... 187 Center support .................................................................................................................................. 188 Lubricating oil relief valve .................................................................................................................... 189 Axle ............................................................................................................................................ 190 Differential .................................................................................................................................... 194 Final drive ..................................................................................................................................... 204 Steering system ..................................................................................................................................... 206 Layout of steering parts ........................................................................................................................ 206 Steering column ................................................................................................................................. 207 Joystick steering lever linkage ................................................................................................................. 208 Steering pump ................................................................................................................................... 209 Steering control valve .......................................................................................................................... 221 Orbitrol valve .................................................................................................................................. 231 Stop valve ...................................................................................................................................... 237 Emergency steering piping diagram ............................................................................................................... 238 Diverter valve .................................................................................................................................. 239 Emergency steering pump ......................................................................................................................... 243 Brake system ........................................................................................................................................ 244 Layout of brake parts ........................................................................................................................... 244 Charge valve .................................................................................................................................... 246 Brake valve ..................................................................................................................................... 252 Slack adjuster .................................................................................................................................. 257 Accumulator (for brake) ......................................................................................................................... 260 Brake ........................................................................................................................................... 261 Parking brake control ........................................................................................................................... 263 Parking brake ................................................................................................................................... 264 Parking brake solenoid valve .................................................................................................................... 266 Parking brake emergency release valve ........................................................................................................... 269 Undercarriage and frame ............................................................................................................................. 270 Axle mount ...................................................................................................................................... 270 Center hinge pin ................................................................................................................................ 271 Tire ............................................................................................................................................ 273 Hydraulic system .................................................................................................................................... 275 Hydraulic component layout ...................................................................................................................... 275 Work equipment control .......................................................................................................................... 277 Hydraulic tank .................................................................................................................................. 279 Double type gear pump ........................................................................................................................... 282 Work equipment pump ............................................................................................................................. 283 Control valve ................................................................................................................................... 304 CLSS ............................................................................................................................................ 313 Hydraulic circuit diagram and names of valves ................................................................................................... 317 Accumulator charge valve ........................................................................................................................ 329 Work equipment lock solenoid valve .............................................................................................................. 333 Accumulator (for PPC circuit) ................................................................................................................... 334 Accumulator (for ECSS) .......................................................................................................................... 335 Work equipment ...................................................................................................................................... 336 Work equipment linkage .......................................................................................................................... 336 Bucket .......................................................................................................................................... 337 Bucket positioner and boom positioner ........................................................................................................... 339 Lubrication of work equipment ................................................................................................................... 340 Cab and its attachments ............................................................................................................................. 342 ROPS cab ........................................................................................................................................ 342 Electrical system ................................................................................................................................... 343 Engine control system ........................................................................................................................... 343 Preheating system ............................................................................................................................... 345 Power mode selector circuit ..................................................................................................................... 347 Engine output limit function .................................................................................................................... 348 Automatic warm-up function ...................................................................................................................... 349 Parking brake control system .................................................................................................................... 350 System operating lamp function .................................................................................................................. 352 Battery disconnect switch function .............................................................................................................. 354 Backup lamp and brake lamp ...................................................................................................................... 356 Clearance lamp and headlamp ..................................................................................................................... 358 Working lamp .................................................................................................................................... 359 Horn circuit .................................................................................................................................... 360 Wiper and window washer circuit ................................................................................................................. 361 Transmission controller system .................................................................................................................. 364 Work equipment control system ................................................................................................................... 389 Machine monitor system .......................................................................................................................... 409 Rear view monitor system ........................................................................................................................ 433 KOMTRAX system .................................................................................................................................. 436 System component parts .......................................................................................................................... 439 Sensor .......................................................................................................................................... 473 20 Standard value tables ................................................................................................................................ 497 Table of contents ................................................................................................................................... 498 Standard service value table ........................................................................................................................ 499 Standard value table for engine ................................................................................................................. 499 Standard value table for machine ................................................................................................................ 501 Standard value table for electrical system ...................................................................................................... 516 30 Testing and adjusting ................................................................................................................................ 531 Table of contents ................................................................................................................................... 532 General information on testing and adjusting ........................................................................................................ 534 Tools for testing and adjusting ................................................................................................................. 534 Sketch of tools for testing and adjusting ....................................................................................................... 539 Engine and cooling system ........................................................................................................................... 541 Testing engine speed ............................................................................................................................ 541 Testing boost pressure .......................................................................................................................... 543 Testing exhaust gas temperature ................................................................................................................. 545 Testing exhaust gas color ....................................................................................................................... 547 Testing and adjusting valve clearance ........................................................................................................... 550 Testing compression pressure .................................................................................................................... 552 Testing blowby pressure ......................................................................................................................... 555 Testing engine oil pressure ..................................................................................................................... 557 Testing EGR valve and KVGT driving oil pressure ................................................................................................. 559 Testing fuel pressure ........................................................................................................................... 561 Testing fuel return rate and leakage ............................................................................................................ 563 Bleeding air from fuel system ................................................................................................................... 567 Testing fuel circuit for leakage ................................................................................................................ 569 Handling cylinder cutout mode operation ......................................................................................................... 570 Handling no injection cranking operation ........................................................................................................ 571 Testing of KDPF and muffler stack for looseness and damage ...................................................................................... 572 Testing of installed condition of cylinder head and manifolds ................................................................................... 573 Testing engine piping for damage and looseness .................................................................................................. 574 Replacing and adjusting belt for alternator and air conditioner compressor ...................................................................... 575 Procedures for cleaning fuel doser .............................................................................................................. 576 Writing compensation values at replacement of injector and engine controller .................................................................... 579 Power train ......................................................................................................................................... 583 Adjusting transmission output speed sensor ...................................................................................................... 583 Adjusting transmission input speed sensor ....................................................................................................... 584 Flushing procedure for torque converter and transmission hydraulic circuit ...................................................................... 585 Retrieval of disabled machine due to transmission valve failure ................................................................................. 587 Testing oil leakage from axle final drive ....................................................................................................... 589 Testing drive shaft for looseness, backlash, and damage ......................................................................................... 590 Testing and adjusting power train oil pressure .................................................................................................. 591 Steering system ..................................................................................................................................... 605 Testing directional lever ....................................................................................................................... 605 Testing steering wheel .......................................................................................................................... 606 Testing work equipment control lever ............................................................................................................ 608 Testing and adjusting steering circuit oil pressure ............................................................................................. 610 Bleeding air from steering cylinder circuit. .................................................................................................... 613 Testing and adjusting steering stopper valve .................................................................................................... 614 Brake system ........................................................................................................................................ 616 Testing brake pedal ............................................................................................................................. 616 Testing and adjusting brake pedal linkage ....................................................................................................... 617 Adjustment procedure of transmission cut-off proximity switch of left brake pedal ............................................................... 618 Testing braking performance ..................................................................................................................... 619 Testing and adjusting of accumulator charge pressure ............................................................................................ 620 Testing wheel brake oil pressure ................................................................................................................ 622 Testing lowering of wheel brake pressure ........................................................................................................ 623 Testing wear of wheel brake disc ................................................................................................................ 626 Bleeding air from wheel brake circuit ........................................................................................................... 627 Releasing remaining pressure in brake accumulator circuit ....................................................................................... 629 Testing parking brake performance ............................................................................................................... 630 Testing parking brake oil pressure .............................................................................................................. 631 Testing wear of parking brake disc .............................................................................................................. 633 Method of releasing parking brake manually ...................................................................................................... 634 Hydraulic system .................................................................................................................................... 636 Testing fan speed ............................................................................................................................... 636 Testing fan pump circuit oil pressure ........................................................................................................... 637 Bleeding air from hydraulic fan circuit ......................................................................................................... 639 Testing work equipment EPC oil pressure ......................................................................................................... 641 Testing and adjusting work equipment oil pressure ............................................................................................... 643 Bleeding air from work equipment circuit ........................................................................................................ 649 Releasing remaining pressure from work equipment circuit ........................................................................................ 650 Checking of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ..................................... 651 Work equipment ...................................................................................................................................... 656 Testing and adjusting bucket position detection lever ........................................................................................... 656 Testing and adjusting boom position detection lever ............................................................................................. 657 Electrical system ................................................................................................................................... 658 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor .......................................................... 658 Special functions of machine monitor ............................................................................................................ 660 Adjusting rearview camera angle ................................................................................................................. 753 Handling voltage circuit of engine controller ................................................................................................... 754 Handling battery disconnect switch .............................................................................................................. 755 Testing diodes .................................................................................................................................. 756 Pm clinic ........................................................................................................................................... 757 Pm Clinic service ............................................................................................................................... 757 Check sheet ..................................................................................................................................... 758 40 Troubleshooting ...................................................................................................................................... 765 Table of contents ................................................................................................................................... 766 General information on troubleshooting .............................................................................................................. 776 Troubleshooting points .......................................................................................................................... 776 Sequence of events in troubleshooting ........................................................................................................... 778 Check before troubleshooting .................................................................................................................... 780 Inspection procedure before troubleshooting ..................................................................................................... 782 Preparation work for troubleshooting of electrical system ....................................................................................... 799 Classification and procedures for troubleshooting ............................................................................................... 805 Symptom and troubleshooting numbers ............................................................................................................. 808 Information in troubleshooting table ............................................................................................................ 811 Connector list and layout ....................................................................................................................... 813 Connector contact identification ................................................................................................................ 828 T-branch box and T-branch adapter table ......................................................................................................... 864 Fuse location table ............................................................................................................................. 870 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................................................................... 873 Precautions on troubleshooting of machine monitor ............................................................................................... 876 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ......................................................... 878 Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................................. 883 Fabrication of short-circuit connector (for CA1883 and CA3135) .................................................................................. 884 Failure codes table ............................................................................................................................. 885 Troubleshooting by failure code (Display of code) ................................................................................................... 900 Failure code [1500L0] Double Engagement of T/M Clutches ......................................................................................... 900 Failure code [15B0NX] Transmission Oil Filter Clogging .......................................................................................... 901 Failure code [15SAL1] Release Trouble of ECMV (Forward) ......................................................................................... 902 Failure code [15SALH] Malfunction of ECMV (Forward) ............................................................................................. 904 Failure code [15SBL1] Release Trouble of ECMV (Reverse) ......................................................................................... 906 Failure code [15SBLH] Malfunction of ECMV (Reverse) ............................................................................................. 908 Failure code [15SEL1] Release Trouble of ECMV (1st clutch) ...................................................................................... 910 Failure code [15SELH] Malfunction of ECMV (1st) ................................................................................................. 912 Failure code [15SFL1] Release Trouble of ECMV (2nd) ............................................................................................. 914 Failure code [15SFLH] Malfunction of ECMV (2nd) ................................................................................................. 916 Failure code [15SGL1] Release Trouble of ECMV (3rd) ............................................................................................. 918 Failure code [15SGLH] Malfunction of ECMV (3rd) ................................................................................................. 920 Failure code [15SHL1] Release Trouble of ECMV (4th) ............................................................................................. 922 Failure code [15SHLH] Malfunction of ECMV (4th) ................................................................................................. 924 Failure code [2F00MA] Failure of Parking Brake Circuit .......................................................................................... 926 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...................................................................................... 929 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....................................................................................... 931 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................................. 933 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................ 934 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................................. 935 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................ 936 Failure code [879CKA] Ventilating Sensor Open Circuit ........................................................................................... 937 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................................................... 938 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..................................................................................... 939 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................ 940 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................ 941 Failure code [989A00] Engine Overrun Prevention Activated ....................................................................................... 942 Failure code [989L00] Engine Controller Lock Caution 1 .......................................................................................... 943 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................................... 944 Failure code [989N00] Engine Controller Lock Caution 3 .......................................................................................... 945 Failure code [A1U0N3] HC Desorb Request 1 ....................................................................................................... 946 Failure code [A1U0N4] HC Desorb Request 2 ....................................................................................................... 948 Failure code [AA10NX] Air Cleaner Clogging ...................................................................................................... 950 Failure code [B@BAZG] Eng Oil Press Low ......................................................................................................... 952 Failure code [B@BCNS] Eng Water Overheat ........................................................................................................ 953 Failure code [B@BCZK] Eng Water Level Low ....................................................................................................... 954 Failure code [B@CENS] T/C Oil Temp. Overheat .................................................................................................... 956 Failure code [B@HANS] HYD Oil Temp. Overheat .................................................................................................... 957 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................................... 958 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................................ 959 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................................. 961 Failure code [CA131] Throttle Sensor High Error ................................................................................................. 963 Failure code [CA132] Throttle Sensor Low Error .................................................................................................. 965 Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................................ 967 Failure code [CA141] Eng Oil Press Sensor Low Error ............................................................................................. 969 Failure code [CA144] Coolant Temp Sens High Error ............................................................................................... 971 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................................ 973 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................................. 975 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................................. 977 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................................. 979 Failure code [CA221] Ambient Press Sens High Error .............................................................................................. 981 Failure code [CA222] Ambient Press Sens Low Error ............................................................................................... 983 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................................ 985 Failure code [CA234] Eng Overspeed .............................................................................................................. 986 Failure code [CA238] Ne Speed Sensor Supply Volt Error .......................................................................................... 987 Failure code [CA239] Ne Speed Sens Supply Volt High Error ....................................................................................... 988 Failure code [CA271] IMV/PCV1 Short Error ....................................................................................................... 989 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................................ 990 Failure code [CA273] PCV2 Short Error ........................................................................................................... 991 Failure code [CA274] PCV2 Open Error ............................................................................................................ 992 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................................................... 993 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................................................... 995 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................................................... 997 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................................................... 999 Failure code [CA331] Inj #2(L#2) Open/Short Error ...............................................................................................1001 Failure code [CA332] Inj #4(L#4) Open/Short Error ...............................................................................................1003 Failure code [CA343] ECM Critical Internal Failure ..............................................................................................1005 Failure code [CA351] Injectors Drive Circuit Error ..............................................................................................1006 Failure code [CA352] Sensor 1 Supply Volt Low Error .............................................................................................1007 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................................1009 Failure code [CA357] Mass Air Flow Sensor Low Error .............................................................................................1011 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................................1013 Failure code [CA431] Idle Validation Sw Error ...................................................................................................1014 Failure code [CA432] Idle Validation Process Error ..............................................................................................1017 Failure code [CA441] Battery Voltage Low Error ..................................................................................................1020 Failure code [CA442] Battery Voltage High Error .................................................................................................1022 Failure code [CA449] Rail Press Very High Error .................................................................................................1023 Failure code [CA451] Rail Press Sensor High Error ...............................................................................................1024 Failure code [CA452] Rail Press Sensor Low Error ................................................................................................1026 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................................1028 Failure code [CA516] Rail Press Sens Sup Volt Low Error .........................................................................................1030 Failure code [CA553] Rail Press High Error ......................................................................................................1032 Failure code [CA555] Crankcase Press High Error 2 ...............................................................................................1033 Failure code [CA556] Crankcase Press High Error 3 ...............................................................................................1034 Failure code [CA559] Rail Press Low Error .......................................................................................................1035 Failure code [CA595] Turbo Speed High Error 2 ...................................................................................................1039 Failure code [CA687] Turbo Speed Low Error ......................................................................................................1040 Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................................................1042 Failure code [CA691] Intake Air Temp Sens High Error ............................................................................................1044 Failure code [CA692] Intake Air Temp Sens Low Error .............................................................................................1046 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................................1048 Failure code [CA698] ECM Int Temp Sensor Low Error ..............................................................................................1049 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................................1050 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................................1051 Failure code [CA1117] Persistent Data Lost Error ................................................................................................1053 Failure code [CA1664] KDOC Malfunction ..........................................................................................................1054 Failure code [CA1691] Regeneration Ineffective ..................................................................................................1057 Failure code [CA1695] Sensor 5 Supply Volt High Error ...........................................................................................1060 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................................................1061 Failure code [CA1843] Crankcase Press Sens High Error ...........................................................................................1063 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................................................1065 Failure code [CA1879] KDPF Delta P Sensor High Error ............................................................................................1067 Failure code [CA1881] KDPF Delta P Sensor Low Error .............................................................................................1069 Failure code [CA1883] KDPF Delta P Sens In Range Error ..........................................................................................1071 Failure code [CA1921] KDPF Soot Load High Error 1 ...............................................................................................1074 Failure code [CA1922] KDPF Soot Load High Error 2 ...............................................................................................1077 Failure code [CA1923] Dosing Fuel Valve 1 High Error ............................................................................................1082 Failure code [CA1924] Dosing Fuel Valve 1 Low Error .............................................................................................1084 Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ........................................................................................1087 Failure code [CA1927] Dosing Fuel Press Sens High Error .........................................................................................1089 Failure code [CA1928] Dosing Fuel Press Sens Low Error ..........................................................................................1091 Failure code [CA1942] Crankcase Press Sens In Range Error .......................................................................................1093 Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...........................................................................................1094 Failure code [CA1977] Fuel Doser Open/Short Error ...............................................................................................1096 Failure code [CA1993] KDPF Delta Pressure Low Error .............................................................................................1098 Failure code [CA2185] Throt Sensor Sup Volt High Error ..........................................................................................1101 Failure code [CA2186] Throt Sensor Sup Volt Low Error ...........................................................................................1103 Failure code [CA2249] Rail Press Very Low Error .................................................................................................1105 Failure code [CA2265] Fuel Feed Pump Open Error .................................................................................................1106 Failure code [CA2266] Fuel Feed Pump Short Error ................................................................................................1108 Failure code [CA2271] EGR Valve Pos Sens High Error .............................................................................................1110 Failure code [CA2272] EGR Valve Pos Sens Low Error ..............................................................................................1112 Failure code [CA2349] EGR Valve Solenoid Open Error .............................................................................................1114 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................................1116 Failure code [CA2357] EGR Valve Servo Error .....................................................................................................1118 Failure code [CA2381] KVGT Pos Sens High Error ..................................................................................................1119 Failure code [CA2382] KVGT Pos Sens Low Error ...................................................................................................1121 Failure code [CA2383] KVGT Solenoid Open Error ..................................................................................................1123 Failure code [CA2386] KVGT Solenoid Short Error .................................................................................................1125 Failure code [CA2387] KVGT Servo Error ..........................................................................................................1127 Failure code [CA2555] Grid Htr Relay Volt Low Error .............................................................................................1128 Failure code [CA2556] Grid Htr Relay Volt High Error ............................................................................................1130 Failure code [CA2637] KDOC Face Plugging ........................................................................................................1132 Failure code [CA2639] Manual Stationary Regeneration Request ....................................................................................1134 Failure code [CA2732] Dosing Fuel Valve 2 High Error ............................................................................................1137 Failure code [CA2733] Dosing Fuel Valve 2 Low Error .............................................................................................1139 Failure code [CA2741] Dosing Fuel Valve Swap Error ..............................................................................................1141 Failure code [CA2765] Inj Trim Data Error .......................................................................................................1143 Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...........................................................................................1144 Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ..........................................................................................1147 Failure code [CA3133] KDPF Outlet Press Sens High Error .........................................................................................1152 Failure code [CA3134] KDPF Outlet Press Sens Low Error ..........................................................................................1154 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .....................................................................................1156 Failure code [CA3167] Fuel Doser Degradation ....................................................................................................1159 Failure code [CA3251] KDOC Inlet Temp High Error ................................................................................................1162 Failure code [CA3253] KDOC Temp Error - Non Regeneration ........................................................................................1165 Failure code [CA3254] KDOC Outlet Temp High Error 1 .............................................................................................1168 Failure code [CA3255] KDPF Temp Error - Non Regeneration ........................................................................................1171 Failure code [CA3256] KDPF Outlet Temp High Error 1 .............................................................................................1175 Failure code [CA3311] KDOC Outlet Temp High Error 2 .............................................................................................1178 Failure code [CA3312] KDPF Outlet Temp High Error 2 .............................................................................................1181 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ..........................................................................................1184 Failure code [CA3314] KDOC Inlet Temp Sens High Error ...........................................................................................1187 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .......................................................................................1190 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...........................................................................................1194 Failure code [CA3317] KDOC Outlet Temp Sens High Error ..........................................................................................1197 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ......................................................................................1200 Failure code [CA3319] KDPF Outlet Temp Sens High Error ..........................................................................................1203 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...........................................................................................1206 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ......................................................................................1208 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ..................................................................................1211 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...................................................................................1213 Failure code [D160KA] Disconnection of Backup Lamp Relay Output .................................................................................1215 Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ..................................................................................1217 Failure code [D160KY] Hot Short of Backup Lamp Relay Output .....................................................................................1219 Failure code [D191KA] Disconnection of Neutral Output Relay .....................................................................................1221 Failure code [D191KB] Ground Fault of Neutral Output Relay ......................................................................................1223 Failure code [D191KY] Hot Short of Neutral Output Relay .........................................................................................1225 Failure code [D192KA] Disconnection of ECSS Solenoid ............................................................................................1227 Failure code [D192KB] Ground Fault of ECSS Solenoid .............................................................................................1229 Failure code [D192KY] Hot Short of ECSS Solenoid ................................................................................................1231 Failure code [D193KA] Disconnection of J/S Solenoid Cut Relay ...................................................................................1232 Failure code [D193KB] Ground Fault of J/S Solenoid Cut Relay ....................................................................................1234 Failure code [D193KY] Hot Short of J/S Solenoid Cut Relay .......................................................................................1236 Failure code [D193MC] Malfunction of J/S Solenoid Cut Relay .....................................................................................1238 Failure code [D19JKZ] Personal Code Relay Abnormality ...........................................................................................1240 Failure code [D1E6KA] Disconnection of Parking Brake Relay ......................................................................................1242 Failure code [D1E6KB] Ground Fault of Parking Brake Relay .......................................................................................1244 Failure code [D1E6KY] Hot Short of Parking Brake Relay ..........................................................................................1246 Failure code [D5ZHKA] Failure of Key SW C Signal ................................................................................................1248 Failure code [D5ZHKB] Key SW C Signal Short Circuit .............................................................................................1250 Failure code [D5ZHKZ] Failure of Key SW C Signal ................................................................................................1252 Failure code [D5ZHL6] Disconnection of Key SW C .................................................................................................1254 Failure code [D811MC] KOMTRAX Error .............................................................................................................1256 Failure code [D862KA] GPS Antenna Open Circuit ..................................................................................................1257 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .....................................................................................1258 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ....................................................................................1260 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...................................................................................................1262 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .....................................................................................................1263 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................................................................1265 Failure code [DAF0MB] Monitor ROM Abnormality ...................................................................................................1266 Failure code [DAF0MC] Monitor Error .............................................................................................................1267 Failure code [DAF3KK] Controller Power Source Low (MON) .........................................................................................1268 Failure code [DAF8KB] Camera Power Supply Short Circuit .........................................................................................1270 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ....................................................................................1271 Failure code [DAFGMC] GPS Module Error ..........................................................................................................1273 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) .........................................................................................1274 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ........................................................................................1276 Failure code [DAFQKR] CAN2 Discon (Monitor) .....................................................................................................1278 Failure code [DAQ0KK] Controller Power Source Low (T/M) .........................................................................................1279 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ..................................................................................1282 Failure code [DAQ0MC] T/M Con Error .............................................................................................................1283 Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .........................................................................................1284 Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ...........................................................................................1286 Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ...................................................................................1289 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ....................................................................................1291 Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) .........................................................................................1292 Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ........................................................................................1294 Failure code [DAQQKR] CAN2 Discon (Transmission Con) ............................................................................................1296 Failure code [DAQRKR] CAN1 Discon (Transmission Con) ............................................................................................1297 Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ...................................................................................1298 Failure code [DAZ9KQ] A/C Model Selection Abnormality ...........................................................................................1299 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ..................................................................................................1300 Failure code [DB2QKR] CAN2 Discon (Engine Con) ..................................................................................................1301 Failure code [DB2RKR] CAN1 Discon (Engine Con) ..................................................................................................1306 Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................................................................1311 Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ..................................................................................1314 Failure code [DB90MC] BBC Error .................................................................................................................1315 Failure code [DB91KA] Disconnection of Key SW ACC (BBC) .........................................................................................1316 Failure code [DB92KK] Solenoid Power Source Low (BBC) ...........................................................................................1318 Failure code [DB95KX] Failure of 5 V Power Source 1 .............................................................................................1320 Failure code [DB96KX] Failure of 5 V Power Source 2 .............................................................................................1324 Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ....................................................................................1328 Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) .........................................................................................1329 Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ........................................................................................1331 Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .............................................................................................1333 Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .............................................................................................1334 Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ...................................................................................1335 Failure code [DBE5KX] Failure of 5V Power Source ................................................................................................1336 Failure code [DBE6KX] Failure of 24 V Power Source ..............................................................................................1338 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................................................................1340 Failure code [DDA8KY] Hot Short of Throttle Lock Set SW .........................................................................................1344 Failure code [DDA9KY] Hot Short of Throttle Lock Resume SW ......................................................................................1346 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................................................................1348 Failure code [DDB6L4] Neutral Signal Malfunction ................................................................................................1350 Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ...................................................................................1353 Failure code [DDE5KA] Failure of Emergency Steering Signal ......................................................................................1357 Failure code [DDK3KA] FNR SW Input Signal Disconnection .........................................................................................1359 Failure code [DDK3KB] FNR SW Input Signal Short Circuit .........................................................................................1364 Failure code [DDK4KA] J/S FNR Input Signal Disconnection ........................................................................................1368 Failure code [DDK4KB] J/S FNR Input Signal Short Circuit ........................................................................................1371 Failure code [DDK5L4] Failure of J/S Shift Up/Down SW ...........................................................................................1373 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ......................................................................................1375 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ......................................................................................1378 Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................................................................1380 Failure code [DDT0L4] Failure of Shift Mode Select SW ...........................................................................................1384 Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal .................................................................................1388 Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal .....................................................................................1392 Failure code [DDW9LD] Ground Fault of Kickdown Switch ...........................................................................................1396 Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW .........................................................................................1400 Failure code [DF10KA] Disconnection of Shift Lever Input ........................................................................................1404 Failure code [DF10KB] Ground Fault of Shift Lever Input .........................................................................................1407 Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor .....................................................................................1409 Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ......................................................................................1411 Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ......................................................................................1413 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ....................................................................................1415 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .........................................................................................1416 Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor .....................................................................................1418 Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ......................................................................................1420 Failure code [DH21KA] Failure of Loader Pump Press. Sensor ......................................................................................1422 Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ...................................................................................1424 Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit .....................................................................................1426 Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor .................................................................................1428 Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ...................................................................................1430 Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. ...................................................................................1432 Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor .................................................................................1434 Failure code [DHT2L6] Failure of T/M Oil Filter Sensor Circuit ..................................................................................1436 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .................................................................................1437 Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ................................................................................1440 Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ....................................................................................1443 Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit .................................................................................1445 Failure code [DHT8ZG] Steering Oil Pressure Low .................................................................................................1447 Failure code [DJF1KA] Disconnection of Fuel Level Sensor ........................................................................................1448 Failure code [DK55KA] Failure of FNR Lever Potentio .............................................................................................1450 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...................................................................................1452 Failure code [DK55L5] Failure of FNR Lever Potentio .............................................................................................1454 Failure code [DK59KA] Failure of Boom Lever Potentio (Main) .....................................................................................1455 Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ...................................................................................1460 Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................................................................1465 Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ......................................................................................1472 Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ....................................................................................1478 Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ...................................................................................1483 Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) .................................................................................1488 Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................................................................1493 Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ....................................................................................1500 Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ..................................................................................1505 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ......................................................................................1510 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ....................................................................................1515 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ..................................................................................1519 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) .......................................................................................1525 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) .....................................................................................1530 Failure code [DK5FKA] Failure of J/S Lever Potentio (Main) ......................................................................................1534 Failure code [DK5FKY] Hot Short of J/S Lever Potentio (Main) ....................................................................................1537 Failure code [DK5FL8] J/S Lever Potentio (Main & Sub) Disagree ..................................................................................1540 Failure code [DK5GKA] Failure of J/S Lever Potentio (Sub) .......................................................................................1544 Failure code [DK5GKY] Hot Short of J/S Lever Potentio (Sub) .....................................................................................1547 Failure code [DKA0KA] Failure of Boom Angle Sensor ..............................................................................................1550 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ....................................................................................1552 Failure code [DKA0L0] Boom Angle Sensor Dislocation .............................................................................................1554 Failure code [DKA1KA] Failure of Bucket Angle Sensor ............................................................................................1556 Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ..................................................................................1558 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ...................................................................................1560 Failure code [DLF1LC] Failure of T/M Input Speed Sensor .........................................................................................1562 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ................................................................................1564 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ......................................................................................1566 Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ................................................................................1568 Failure code [DLT3LC] Failure of Output Speed Sensor (Main) .....................................................................................1570 Failure code [DPQ1KR] LIN Discon (Switch Panel) .................................................................................................1572 Failure code [DPQ2KR] LIN Discon (LED Unit) .....................................................................................................1575 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ............................................................................................1578 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ..................................................................................................1581 Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .....................................................................................1583 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...................................................................................1587 Failure code [DV00KB] Ground Fault of Buzzer Output .............................................................................................1591 Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. ..................................................................................1593 Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. ...................................................................................1594 Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. ......................................................................................1595 Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve ...................................................................................1596 Failure code [DW2BLH] Malfunction of Main Flow Selector Valve ...................................................................................1597 Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................................................................1598 Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) .................................................................................1600 Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................................................................1602 Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ................................................................................1604 Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) .................................................................................1606 Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ....................................................................................1608 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...................................................................................1610 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ................................................................................1612 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...................................................................................1614 Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ...................................................................................1616 Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................................................................1618 Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ...................................................................................1620 Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid .....................................................................................1622 Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ....................................................................................1623 Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. .......................................................................................1625 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ....................................................................................1626 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid .....................................................................................1628 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ........................................................................................1630 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................................................................1632 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ....................................................................................1636 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) .......................................................................................1640 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) .................................................................................1644 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ..................................................................................1648 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) .....................................................................................1652 Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ...................................................................................1656 Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................................................................1658 Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ...................................................................................1660 Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid .................................................................................1662 Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ..................................................................................1664 Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid .....................................................................................1666 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ...................................................................................1667 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................................................................1669 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .......................................................................................1671 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ......................................................................................1673 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) .......................................................................................1675 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ..........................................................................................1677 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ......................................................................................1679 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .......................................................................................1681 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ..........................................................................................1683 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ......................................................................................1685 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) .......................................................................................1686 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ..........................................................................................1688 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ..................................................................................1690 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ...................................................................................1692 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ......................................................................................1694 Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ..................................................................................1696 Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ...................................................................................1698 Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ......................................................................................1700 Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ......................................................................................1702 Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) .......................................................................................1704 Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ..........................................................................................1706 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...................................................................................1708 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ....................................................................................1710 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .......................................................................................1712 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................................................................1714 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ....................................................................................1716 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) .......................................................................................1718 Failure code [DXHLKA] Disconnection of J/S Right EPC Solenoid ...................................................................................1720 Failure code [DXHLKB] Ground Fault of J/S Right EPC Solenoid ....................................................................................1722 Failure code [DXHLKY] Hot Short of J/S Right EPC Solenoid .......................................................................................1724 Failure code [DXHMKA] Disconnection of J/S Left EPC Solenoid ....................................................................................1726 Failure code [DXHMKB] Ground Fault of J/S Left EPC Solenoid .....................................................................................1728 Failure code [DXHMKY] Hot Short of J/S Left EPC Solenoid ........................................................................................1730 Failure code [LA00L3] Failure of Fan Reverse ....................................................................................................1732 Troubleshooting of electrical system (E-mode) .......................................................................................................1733 E-1 Engine does not start (Engine does not crank) ...............................................................................................1733 E-2 Manual preheating system does not work ......................................................................................................1740 E-3 Automatic preheating system does not work ...................................................................................................1743 E-4 While preheating is working, preheating monitor does not light up ...........................................................................1745 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ................................................................1747 E-6 LCD unit on machine monitor displays nothing ................................................................................................1750 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) .......................................................1752 E-8 LCD on machine monitor does not display properly ............................................................................................1754 E-9 Meter unit display on machine monitor is abnormal ...........................................................................................1756 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...........................................................................1759 E-11 Caution LED on machine monitor is abnormal .................................................................................................1762 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...................................................1764 E-13 Two switches operation of switch panel on machine monitor does not function ................................................................1766 E-14 Switch panel buzzer of machine monitor is abnormal .........................................................................................1769 E-15 Rearview monitor does not light up or backlight flickers ...................................................................................1771 E-16 Rearview monitor images are not displayed clearly ..........................................................................................1774 E-17 Rearview monitor brightness cannot be adjusted .............................................................................................1777 E-18 Night lighting lamp of rearview monitor is abnormal ........................................................................................1780 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly .......................................................1782 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position .........................................1783 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ..............................................1787 E-22 Air cleaner clogging indicator lamp does not light .........................................................................................1789 E-23 Radiator coolant level caution lamp does not light .........................................................................................1790 E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ..................1792 E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ....1794 E-26 Fuel level gauge does not indicate correct level ...........................................................................................1795 E-27 Seat belt caution lamp indication is abnormal ..............................................................................................1797 E-28 Horn does not sound ........................................................................................................................1798 E-29 Horn does not stop sounding ................................................................................................................1800 E-30 Alarm buzzer does not sound ................................................................................................................1801 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................................................................1802 E-32 Kickdown does not work when kickdown switch is turned ON ...................................................................................1803 E-33 The hold switch does not work when it is pressed ...........................................................................................1805 E-34 Transmission is always shifted to Neutral, or the brake drags when parking brake applies and FR drive is selected ..........................1807 E-35 Transmission cut-off mode is not selected or not released ..................................................................................1810 E-36 Transmission cut-off setting cannot be released ............................................................................................1812 E-37 FNR switch mode is not selected or not released ............................................................................................1814 E-38 When operating engine mode selector switch, engine mode selector function does not operate properly ........................................1816 E-39 Flow of loader pump does not increase from the minimum rate ................................................................................1818 E-40 ECSS function cannot be selected or cannot be released .....................................................................................1819 E-41 None of headlamp, clearance lamp, and tail lamp lights .....................................................................................1821 E-42 Clearance lamp and tail lamp do not light up or go out .....................................................................................1823 E-43 Both High and Low beams of headlamp do not light up or go out ..............................................................................1826 E-44 Low beam of headlamp does not light up or go out ...........................................................................................1830 E-45 High beam of headlamp does not light up or go out ..........................................................................................1832 E-46 Front working lamp does not light up or go out .............................................................................................1834 E-47 Rear working lamp does not light up or go out ..............................................................................................1837 E-48 All of turn signal lamps and hazard lamps do not light up or go out ........................................................................1840 E-49 Turn signal lamps do not light up or go out ................................................................................................1843 E-50 Hazard lamp does not light up or go out ....................................................................................................1846 E-51 Brake lamp does not light up or stays lighted ..............................................................................................1849 E-52 Backup lamp does not light or continues to light ...........................................................................................1852 E-53 Backup buzzer does not sound or continues to sound .........................................................................................1855 E-54 Front wiper does not operate ...............................................................................................................1857 E-55 Rear wiper does not operate ................................................................................................................1860 E-56 Window washer does not operate .............................................................................................................1863 E-57 Fuel feed pump does not operate or stop automatically ......................................................................................1866 E-58 KOMTRAX system does not operate properly ...................................................................................................1868 Troubleshooting of hydraulic and mechanical system (H-mode) .........................................................................................1870 Information described in troubleshooting table (H-mode) .........................................................................................1870 System chart of hydraulic and mechanical systems ................................................................................................1871 Failure mode and cause table ....................................................................................................................1875 H-1 Machine does not start ......................................................................................................................1884 H-2 Torque converter lockup clutch is not disengaged (engine stalls) ............................................................................1887 H-3 Torque converter lockup clutch is not engaged ...............................................................................................1888 H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift .........................................1889 H-5 Large shock is made when machine starts or gear is shifted ..................................................................................1892 H-6 Machine starts or gear speed shifts with long time lag ......................................................................................1894 H-7 Torque converter oil temperature is high ....................................................................................................1896 H-8 Machine does not turn .......................................................................................................................1898 H-9 Turning response is poor ....................................................................................................................1902 H-10 Steering wheel is heavy to turn ............................................................................................................1906 H-11 Machine sways or large shocks are made while machine turns .................................................................................1907 H-12 Turning radius differs between right and left turns ........................................................................................1911 H-13 Wheel brakes do not work or are weak .......................................................................................................1912 H-14 Wheel brakes are not released or drag ......................................................................................................1914 H-15 Parking brake does not work or it is weak ..................................................................................................1915 H-16 Parking brake is not released or drags (including emergency release system) ................................................................1916 H-17 Boom does not rise .........................................................................................................................1917 H-18 Boom moves slow or boom lacks lifting force ................................................................................................1919 H-19 Rising boom slows down at certain height ...................................................................................................1921 H-20 Lift cylinders do not serve to hold bucket on ground .......................................................................................1922 H-21 Hydraulic drift of boom is large ...........................................................................................................1923 H-22 Boom moves up and down during operation ....................................................................................................1924 H-23 Bucket does not tilt back ..................................................................................................................1925 H-24 Bucket moves slow or bucket lacks tilt-back force ..........................................................................................1927 H-25 Bucket decelerates during tilt-back operation ..............................................................................................1929 H-26 Bucket cylinder does not hold bucket on ground .............................................................................................1930 H-27 Hydraulic drift of bucket is large .........................................................................................................1931 H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ............................................................1932 H-29 Boom and bucket control levers do not move smoothly and are heavy to move ..................................................................1933 H-30 Operating work equipment causes engine speed to lower significantly or engine to stall .....................................................1934 H-31 Large shocks are made when work equipment starts to move and stops .........................................................................1935 H-32 When certain work equipment stalls hydraulically, other work equipment moves ...............................................................1937 H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces .....................................................................1938 H-34 Fan speed is abnormal (too high or low, or fan does not rotate) ............................................................................1939 H-35 Unusual noise is heard from around fan .....................................................................................................1940 Troubleshooting of engine (S-mode) ..................................................................................................................1941 Information mentioned in troubleshooting table (S mode) .........................................................................................1941 S-1 When starting switch is turned to START position, engine is not cranked .....................................................................1942 S-2 The engine cranks but exhaust smoke does not come out .......................................................................................1943 S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ......................................1944 S-4 Engine startability is poor .................................................................................................................1945 S-5 Engine does not pick-up smoothly ............................................................................................................1948 S-6 Engine stops during operation ...............................................................................................................1951 S-7 Engine runs rough or is unstable ............................................................................................................1953 S-8 Engine lacks power ..........................................................................................................................1954 S-9 KDPF gets clogged in a short time ...........................................................................................................1956 S-10 Engine oil consumption is excessive ........................................................................................................1958 S-11 Engine oil becomes contaminated early ......................................................................................................1959 S-12 Fuel consumption is excessive ..............................................................................................................1960 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...........................................................................1961 S-14 Oil pressure drops .........................................................................................................................1962 S-15 Fuel mixes into engine oil .................................................................................................................1963 S-16 Water mixes into engine oil (milky) ........................................................................................................1964 S-17 Coolant temperature rises too high (overheating) ...........................................................................................1965 S-18 Unusual noise is heard .....................................................................................................................1966 S-19 Vibration is excessive .....................................................................................................................1967 S-20 Air cannot be bled from fuel circuit .......................................................................................................1968 S-21 Active regeneration is executed frequently .................................................................................................1969 S-22 Active regeneration takes a long time ......................................................................................................1970 S-23 White smoke is exhausted during active regeneration ........................................................................................1971 50 Disassembly and assembly .............................................................................................................................1973 Table of contents ...................................................................................................................................1974 General information on disassembly and assembly .....................................................................................................1976 How to read this manual .........................................................................................................................1976 Coating materials list ..........................................................................................................................1978 Special tools list ..............................................................................................................................1982 Sketches of special tools .......................................................................................................................1986 Engine and cooling system ...........................................................................................................................1995 Removal and installation of supply pump assembly ................................................................................................1995 Removal and installation of injector assembly ...................................................................................................2001 Removal and installation of cylinder head assembly ..............................................................................................2021 Removal and installation of engine hood assembly ................................................................................................2042 Removal and installation of radiator core assembly ..............................................................................................2046 Removal and installation of aftercooler .........................................................................................................2049 Removal and installation of hydraulic oil cooler ................................................................................................2052 Removal and installation of power train oil cooler assembly .....................................................................................2056 Removal and installation of engine assembly .....................................................................................................2058 Removal and installation of engine front oil seal ...............................................................................................2065 Removal and installation of engine rear oil seal ................................................................................................2068 Removal and installation of cooling fan and fan motor assembly ..................................................................................2073 Removal and installation of KDPF assembly .......................................................................................................2075 Disassembly and assembly of KDPF assembly .......................................................................................................2078 Removal and installation of KCCV assembly .......................................................................................................2086 Removal and installation of KVGT assembly .......................................................................................................2088 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .....................................................................2092 Removal and installation of air cleaner assembly ................................................................................................2096 Removal and installation of air conditioner compressor assembly .................................................................................2098 Removal and installation of air conditioner condenser assembly ..................................................................................2100 Removal and installation of belt for alternator and air conditioner compressor ..................................................................2102 Removal and installation of fuel tank assembly ..................................................................................................2104 Power train .........................................................................................................................................2106 Removal and installation of power train unit assembly ...........................................................................................2106 Disconnection and connection of power train unit assembly .......................................................................................2111 Disassembly and assembly of input transfer assembly .............................................................................................2115 Disassembly and assembly of torque converter assembly ...........................................................................................2121 Disassembly and assembly of transmission assembly ...............................................................................................2134 Disassembly and assembly of transfer and parking brake assembly .................................................................................2161 Removal and installation of front differential assembly .........................................................................................2177 Disassembly and assembly of differential assembly (with LSD) ....................................................................................2179 Disassembly and assembly of differential assembly (without LSD) .................................................................................2193 Removal and installation of front axle assembly .................................................................................................2204 Removal and installation of rear axle assembly ..................................................................................................2206 Disassembly and assembly of final drive assembly (front and rear) ...............................................................................2208 Steering system .....................................................................................................................................2214 Removal and installation of steering valve assembly .............................................................................................2214 Brake system ........................................................................................................................................2216 Removal and installation of brake assembly (front and rear) .....................................................................................2216 Disassembly and assembly of brake assembly (front and rear) .....................................................................................2218 Disassembly and assembly of slack adjuster assembly .............................................................................................2224 Disassembly and assembly of brake accumulator charge valve assembly .............................................................................2225 Undercarriage and frame .............................................................................................................................2226 Removal and installation of center hinge pin ....................................................................................................2226 Removal and installation of large counterweight assembly ........................................................................................2233 Removal and installation of small counterweight assembly ........................................................................................2235 Hydraulic system ....................................................................................................................................2236 Removal and installation of hydraulic tank assembly .............................................................................................2236 Removal and installation of work equipment pump assembly ........................................................................................2239 Removal and installation of steering and power train pump assembly ..............................................................................2241 Removal and installation of cooling fan pump assembly ...........................................................................................2243 Removal and installation of work equipment control valve assembly ...............................................................................2245 Disassembly and assembly of work equipment control valve assembly ...............................................................................2248 Removal and installation of diverter valve assembly .............................................................................................2251 Disassembly and assembly of steering cylinder assembly ..........................................................................................2253 Disassembly and assembly of work equipment cylinder assembly ....................................................................................2256 Work equipment ......................................................................................................................................2261 Removal and installation of work equipment assembly .............................................................................................2261 Cab and its attachments .............................................................................................................................2265 Removal and installation of operator's cab assembly (separate cab and floor specification) ......................................................2265 Removal and installation of operator's cab glass (stuck window glass) ...........................................................................2269 Removal and installation of operator's seat assembly ............................................................................................2277 Removal and installation of seat belt ...........................................................................................................2279 Removal and installation of air conditioner unit assembly .......................................................................................2280 Electrical system ...................................................................................................................................2285 Removal and installation of machine monitor assembly ............................................................................................2285 Removal and installation of work equipment controller assembly ..................................................................................2286 Removal and installation of rear view monitor assembly ..........................................................................................2288 Removal and installation of engine controller assembly ..........................................................................................2289 Removal and installation of transmission controller assembly ....................................................................................2291 Removal and installation of monitor controller assembly .........................................................................................2292 Removal and installation of mass air flow and temperature sensor ................................................................................2294 Removal and installation of KOMTRAX terminal assembly ...........................................................................................2295 60 Maintenance standard .................................................................................................................................2297 Table of contents ...................................................................................................................................2298 Engine and cooling system ...........................................................................................................................2299 Engine mount and transmission mount .............................................................................................................2299 Joint ...........................................................................................................................................2301 Cooling fan pump ................................................................................................................................2302 Servo valve .....................................................................................................................................2304 Cooling fan motor ...............................................................................................................................2305 Power train .........................................................................................................................................2307 Drive shaft .....................................................................................................................................2307 Torque converter ................................................................................................................................2308 Torque converter regulator valve ................................................................................................................2312 Transmission ....................................................................................................................................2313 Transmission control valve ......................................................................................................................2320 Forward and reverse clutch ECMV and gear speed clutch ECMV ......................................................................................2321 Lockup clutch ECMV ..............................................................................................................................2322 Main relief valve, torque converter relief valve, and main flow selector valve ..................................................................2323 Center support ..................................................................................................................................2325 Lubricating oil relief valve ....................................................................................................................2326 Axle ............................................................................................................................................2327 Differential ....................................................................................................................................2329 Final drive .....................................................................................................................................2335 Steering system .....................................................................................................................................2337 Steering column .................................................................................................................................2337 Steering pump ...................................................................................................................................2338 Steering control valve ..........................................................................................................................2342 Steering cylinder ...............................................................................................................................2343 Diverter valve ..................................................................................................................................2345 Emergency steering pump .........................................................................................................................2346 Brake system ........................................................................................................................................2347 Charge valve ....................................................................................................................................2347 Brake valve .....................................................................................................................................2349 Slack adjuster ..................................................................................................................................2350 Accumulator (for brake) .........................................................................................................................2351 Brake ...........................................................................................................................................2352 Parking brake ...................................................................................................................................2354 Parking brake solenoid valve ....................................................................................................................2356 Undercarriage and frame .............................................................................................................................2357 Axle mount ......................................................................................................................................2357 Center hinge pin ................................................................................................................................2360 Hydraulic system ....................................................................................................................................2362 Hydraulic tank ..................................................................................................................................2362 Double type gear pump ...........................................................................................................................2363 Work equipment pump .............................................................................................................................2365 Control valve ...................................................................................................................................2367 Accumulator charge valve ........................................................................................................................2376 Work equipment ......................................................................................................................................2377 Work equipment linkage ..........................................................................................................................2377 Bucket ..........................................................................................................................................2380 Bucket positioner and boom positioner ...........................................................................................................2382 Work equipment cylinder .........................................................................................................................2383 80 Appendix .............................................................................................................................................2385 Table of contents ...................................................................................................................................2386 Air conditioner components ..........................................................................................................................2387 Precautions for refrigerant .....................................................................................................................2387 Air conditioner component .......................................................................................................................2388 Configuration and function of refrigeration cycle ...............................................................................................2390 Outline of refrigeration cycle ..................................................................................................................2391 Air conditioner unit ............................................................................................................................2393 Dual pressure switch ............................................................................................................................2398 Air conditioner controller ......................................................................................................................2399 Compressor ......................................................................................................................................2400 Condenser .......................................................................................................................................2401 Receiver drier ..................................................................................................................................2402 Sunlight sensor .................................................................................................................................2404 Outer temperature sensor (outside air temperature sensor) .......................................................................................2405 Procedure for testing and troubleshooting .......................................................................................................2406 Circuit diagram and arrangement of connector pins ...............................................................................................2408 Parts and connectors layout .....................................................................................................................2410 Testing with self-diagnosis function ............................................................................................................2415 Testing temperature control system ..............................................................................................................2418 Testing vent (mode) changeover ..................................................................................................................2420 Testing FRESH/RECIRC air changeover .............................................................................................................2422 Check evaporator temperature sensor .............................................................................................................2424 Testing relays ..................................................................................................................................2426 Troubleshooting chart 1 .........................................................................................................................2428 Troubleshooting chart 2 .........................................................................................................................2429 Information in troubleshooting table ............................................................................................................2431 Failure code list related to air conditioner ....................................................................................................2432 Failure code [879AKA] A/C Inner Sensor Open Circuit .............................................................................................2433 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................................2435 Failure code [879BKA] A/C Outer Sensor Open Circuit .............................................................................................2437 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................................2439 Failure code [879CKA] Ventilating Sensor Open Circuit ...........................................................................................2441 Failure code [879CKB] Ventilating Sensor Short Circuit ..........................................................................................2443 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .....................................................................................2445 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................................2447 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................................2450 A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ............................................2453 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................................................2456 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..........................................................2459 A-4 Troubleshooting for FRESH/RECIRC air changeover .............................................................................................2462 Troubleshooting with gauge pressure .............................................................................................................2464 Connection of service tool ......................................................................................................................2467 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit .........................................................2469 Handling of compressor oil ......................................................................................................................2471 90 Diagrams and drawings ................................................................................................................................2473 Table of contents ...................................................................................................................................2474 Hydraulic circuit diagram ...........................................................................................................................2475 Symbols in hydraulic circuit diagram ............................................................................................................2475 Power train hydraulic circuit diagram............................................................................................................2479 Brake hydraulic circuit diagram .................................................................................................................2480 Hydraulic circuit diagram........................................................................................................................2482 Electric circuit diagram ............................................................................................................................2483 Symbols in electric circuit diagram .............................................................................................................2483 Electrical circuit diagram.......................................................................................................................2487 Electrical circuit diagram of floor..............................................................................................................2500 INDEX....................................................................................................................................................2507
KOMATSU WA500-7 WHEEL LOADER SHOP MANUAL SEN05693-03 – PDF DOWNLOAD:
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