Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-16 PDF

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Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-16 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-16 –  PDF DOWNLOAD

Language : English
Pages : 2588
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-16 –  PDF DOWNLOAD

• SERIAL NUMBERS 10001 and up

Cover 3
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 55
Standard tightening torque table 56
List of abbreviation 62
Conversion table 67
01 Specification 73
Table of contents . 74
Specifications 75
Specification drawing . 75
Specification . 77
Weight table 84
Table of fuel, coolant, and lubricants 86
10 Structure and function . 89
Table of contents . 90
Engine and cooling system . 92
Engine related parts 92
KVGT 94
EGR system piping drawing . 100
EGR system circuit diagram 102
EGR valve . 103
EGR cooler 105
KCCV layout drawing . 107
KCCV ventilator . 109
KDPF 111
Engine mount and transmission mount . 115
Joint . 116
Cooling system 117
Cooling fan pump 121
Cooling fan motor . 130
Power train . 137
Power train system 137
Drive shaft . 140
Power train piping drawing 141
Transmission control 142
Torque converter 144
Torque converter regulator valve 151
Transmission 153
Transfer 170
Transmission control valve 172
Forward and reverse clutch ECMV and gear speed clutch ECMV 175
Lockup clutch ECMV 182
Main relief valve, torque converter relief valve, and main flow selector valve 186
Torque converter oil cooler . 191
Center support 192
Lubricating oil relief valve 193
Axle 194
Differential 198
Final drive . 208
Steering system . 210
Layout of steering parts 210
Steering column . 211
Joystick steering lever linkage . 212
Steering pump . 213
Steering control valve 225
Orbitrol valve 235
Stop valve 241
Emergency steering piping diagram . 242
Diverter valve 243
Emergency steering pump . 247
Brake system 248
Layout of brake parts . 248
Charge valve 250
Brake valve . 256
Slack adjuster 261
Accumulator (for brake) . 264
Brake . 265
Parking brake control . 267
Parking brake . 268
Parking brake solenoid valve 270
Parking brake emergency release valve . 273
Undercarriage and frame . 274
Axle mount 274
Center hinge pin 275
Tire 277
Hydraulic system 279
Hydraulic component layout 279
Work equipment control 281
Hydraulic tank 283
Double type gear pump . 286
Work equipment pump . 287
Control valve . 308
CLSS 317
Hydraulic circuit diagram and names of valves . 321
Accumulator charge valve 333
Work equipment lock solenoid valve 337
Accumulator (for PPC circuit) . 338
Accumulator (for ECSS) 339
Work equipment 340
Work equipment linkage 340
Bucket 341
Bucket positioner and boom positioner . 343
Lubrication of work equipment . 344
Cab and its attachments . 346
ROPS cab 346
Electrical system . 347
Engine control system . 347
Preheating system . 349
Power mode selector circuit . 351
Engine output limit function 352
Automatic warm-up function 353
Parking brake control system 354
System operating lamp function 356
Battery disconnect switch function 358
Backup lamp and brake lamp 360
Clearance lamp and headlamp . 362
Working lamp 363
Horn circuit 364
Wiper and window washer circuit . 365
Transmission controller system 368
Work equipment control system . 393
Machine monitor system 413
Rear view monitor system 438
KOMTRAX system 441
System component parts 444
Sensor 478
20 Standard value tables 501
Table of contents . 502
Standard service value table 503
Standard value table for engine . 503
Standard value table for machine 505
Standard value table for electrical system 520
30 Testing and adjusting 535
Table of contents . 536
Precautions before work 538
Related information on testing and adjusting 540
Tools for testing and adjusting . 540
Sketch of tools for testing and adjusting . 547
Engine and cooling system . 549
Testing engine speed 549
Testing boost pressure 551
Testing exhaust gas temperature . 553
Testing exhaust gas color . 555
Testing mass air flow and temperature sensor . 558
Testing and adjusting valve clearance . 560
Testing compression pressure 562
Testing blowby pressure . 565
Testing engine oil pressure . 567
Testing EGR valve and KVGT driving oil pressure . 569
Testing fuel pressure . 571
Testing fuel return rate and leakage 573
Bleeding air from fuel system . 577
Testing fuel circuit for leakage 579
Handling cylinder cutout mode operation . 580
Handling no-injection cranking operation 581
Testing of KDPF and muffler stack for looseness and damage 582
Testing of installed condition of cylinder heads and manifolds 583
Testing engine piping for damage and looseness 584
Replacing and adjusting belt for alternator and air conditioner compressor 585
Procedures for cleaning fuel doser 586
Writing compensation values at replacement of injector and engine controller 589
Writing compensation amount for soot accumulation caused by ash on engine controller 593
Power train . 596
Adjusting transmission output speed sensor 596
Adjusting transmission input speed sensor . 597
Flushing procedure for torque converter and transmission hydraulic circuit 598
Retrieval of disabled machine due to transmission valve failure . 600
Testing oil leakage from axle final drive . 602
Testing drive shaft for looseness, backlash, and damage . 603
Testing and adjusting power train oil pressure 604
Steering system . 618
Testing directional lever . 618
Testing steering wheel 619
Testing work equipment control lever 621
Testing and adjusting steering circuit oil pressure . 623
Bleeding air from steering cylinder circuit. 626
Testing and adjusting steering stopper valve 627
Brake system 629
Testing brake pedal . 629
Testing and adjusting brake pedal linkage . 630
Adjustment procedure of transmission cut-off proximity switch of left brake pedal . 631
Testing braking performance . 632
Testing and adjusting of brake accumulator charge pressure 633
Measuring accumulator nitrogengas pressure and chargingprocedure for accumulatornitrogen gas . 635
Testing wheel brake oil pressure 641
Testing lowering of wheel brake pressure 642
Testing wear of wheel brake disc 645
Bleeding air from wheel brake circuit . 646
Releasing remaining pressure in brake accumulator circuit . 648
Testing parking brake performance . 649
Testing parking brake oil pressure 650
Testing wear of parking brake disc 652
Method of releasing parking brake manually 653
Hydraulic system 655
Testing fan speed . 655
Testing fan pump circuit oil pressure . 656
Bleeding air from hydraulic fan circuit . 658
Testing work equipment EPC oil pressure . 660
Testing and adjusting work equipment oil pressure . 662
Bleeding air from work equipment circuit 668
Releasing remaining pressure from work equipment circuit 669
Testing ECSS accumulator nitrogen gas pressure and charging accumulator with nitrogen gas 670
Work equipment 677
Testing and adjusting bucket position detection lever . 677
Testing and adjusting boom position detection lever . 678
Electrical system . 679
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor 679
Special functions of machine monitor 681
Adjusting rearview camera angle . 773
Handling voltage circuit of engine controller . 774
Handling battery disconnect switch 775
Testing diodes 776
Pm clinic . 777
Pm Clinic service . 777
Check sheet . 778
40 Troubleshooting 785
Table of contents . 786
Precautions before work 796
Related information on troubleshooting 798
Troubleshooting points 798
Sequence of events in troubleshooting . 800
Check before troubleshooting 802
Inspection procedure before troubleshooting . 804
Preparation work for troubleshooting of electrical system . 821
Classification and procedures for troubleshooting . 827
Symptom and troubleshooting numbers . 830
Information in troubleshooting table 833
Connector list and layout . 835
Connector contact identification 850
T-branch box and T-branch adapter table . 889
Fuse location table . 894
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement . 897
Precautions when performing troubleshooting of machine monitor 900
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit . 902
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) . 907
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) . 908
Failure codes table . 909
Troubleshooting by failure code (Display of code) . 924
Failure code [1500L0] Double Engagement of T/M Clutches . 924
Failure code [15B0NX] Transmission Oil Filter Clogging 925
Failure code [15SAL1] Release Trouble of ECMV (Forward) . 926
Failure code [15SALH] Malfunction of ECMV (Forward) . 928
Failure code [15SBL1] Release Trouble of ECMV (Reverse) . 930
Failure code [15SBLH] Malfunction of ECMV (Reverse) . 932
Failure code [15SEL1] Release Trouble of ECMV (1st clutch) 934
Failure code [15SELH] Malfunction of ECMV (1st) . 936
Failure code [15SFL1] Release Trouble of ECMV (2nd) . 938
Failure code [15SFLH] Malfunction of ECMV (2nd) . 940
Failure code [15SGL1] Release Trouble of ECMV (3rd) . 942
Failure code [15SGLH] Malfunction of ECMV (3rd) . 944
Failure code [15SHL1] Release Trouble of ECMV (4th) . 946
Failure code [15SHLH] Malfunction of ECMV (4th) . 948
Failure code [2F00MA] Failure of Parking Brake Circuit 950
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 953
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) . 955
Failure code [879AKA] A/C Inner Sensor Open Circuit . 957
Failure code [879AKB] A/C Inner Sensor Short Circuit 958
Failure code [879BKA] A/C Outer Sensor Open Circuit . 959
Failure code [879BKB] A/C Outer Sensor Short Circuit 960
Failure code [879CKA] Ventilating Sensor Open Circuit . 961
Failure code [879CKB] Ventilating Sensor Short Circuit 962
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit . 963
Failure code [879EMC] Ventilation Damper Abnormality 964
Failure code [879FMC] Air Mix Damper Abnormality 965
Failure code [989A00] Engine Overrun Prevention Activated . 966
Failure code [989L00] Engine Controller Lock Caution 1 967
Failure code [989M00] Engine Controller Lock Caution 2 968
Failure code [989N00] Engine Controller Lock Caution 3 969
Failure code [A1U0N3] HC Desorb Request 1 . 970
Failure code [A1U0N4] HC Desorb Request 2 . 972
Failure code [AA10NX] Air Cleaner Clogging 974
Failure code [AB00KE] Charge Voltage Low . 976
Failure code [AB00KY] Hot Short of Alternator R Terminal . 978
Failure code [B@BAZG] Eng Oil Press Low . 980
Failure code [B@BCNS] Eng Water Overheat 982
Failure code [B@BCZK] Eng Water Level Low . 983
Failure code [B@CENS] T/C Oil Temp. Overheat 985
Failure code [B@HANS] HYD Oil Temp. Overheat 986
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 987
Failure code [CA122] Chg Air Press Sensor High Error 988
Failure code [CA123] Chg Air Press Sensor Low Error . 990
Failure code [CA131] Throttle Sensor High Error . 992
Failure code [CA132] Throttle Sensor Low Error 994
Failure code [CA135] Eng Oil Press Sensor High Error 996
Failure code [CA141] Eng Oil Press Sensor Low Error . 998
Failure code [CA144] Coolant Temp Sens High Error .1000
Failure code [CA145] Coolant Temp Sens Low Error 1002
Failure code [CA153] Chg Air Temp Sensor High Error .1004
Failure code [CA154] Chg Air Temp Sensor Low Error 1006
Failure code [CA187] Sensor 2 Supply Volt Low Error .1008
Failure code [CA221] Ambient Press Sens High Error 1010
Failure code [CA222] Ambient Press Sens Low Error .1012
Failure code [CA227] Sensor 2 Supply Volt High Error 1014
Failure code [CA234] Eng Overspeed 1015
Failure code [CA238] Ne Speed Sensor Supply Volt Error 1016
Failure code [CA239] Ne Speed Sens Supply Volt High Error .1017
Failure code [CA271] IMV/PCV1 Short Error .1018
Failure code [CA272] IMV/PCV1 Open Error 1019
Failure code [CA273] PCV2 Short Error .1020
Failure code [CA274] PCV2 Open Error 1021
Failure code [CA322] Inj #1(L#1) Open/Short Error .1022
Failure code [CA323] Inj #5(L#5) Open/Short Error .1024
Failure code [CA324] Inj #3(L#3) Open/Short Error .1026
Failure code [CA325] Inj #6(L#6) Open/Short Error .1028
Failure code [CA331] Inj #2(L#2) Open/Short Error .1030
Failure code [CA332] Inj #4(L#4) Open/Short Error .1032
Failure code [CA343] ECM Critical Internal Failure 1034
Failure code [CA351] Injectors Drive Circuit Error 1035
Failure code [CA352] Sensor 1 Supply Volt Low Error .1036
Failure code [CA356] Mass Air Flow Sensor High Error 1038
Failure code [CA357] Mass Air Flow Sensor Low Error .1040
Failure code [CA386] Sensor 1 Supply Volt High Error 1042
Failure code [CA431] Idle Validation Sw Error .1043
Failure code [CA432] Idle Validation Process Error 1046
Failure code [CA441] Battery Voltage Low Error 1049
Failure code [CA442] Battery Voltage High Error .1051
Failure code [CA449] Rail Press Very High Error .1052
Failure code [CA451] Rail Press Sensor High Error .1053
Failure code [CA452] Rail Press Sensor Low Error 1055
Failure code [CA515] Rail Press Sens Sup Volt High Error 1057
Failure code [CA516] Rail Press Sens Sup Volt Low Error .1059
Failure code [CA553] Rail Press High Error 1061
Failure code [CA555] Crankcase Press High Error 2 .1062
Failure code [CA556] Crankcase Press High Error 3 .1063
Failure code [CA559] Rail Press Low Error .1064
Failure code [CA595] Turbo Speed High Error 2 .1068
Failure code [CA687] Turbo Speed Low Error 1069
Failure code [CA689] Eng Ne Speed Sensor Error 1071
Failure code [CA691] Intake Air Temp Sens High Error 1073
Failure code [CA692] Intake Air Temp Sens Low Error .1075
Failure code [CA697] ECM Internal Temp Sensor High Error 1077
Failure code [CA698] ECM Int Temp Sensor Low Error 1078
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1079
Failure code [CA778] Eng Bkup Speed Sensor Error 1080
Failure code [CA1117] Persistent Data Lost Error 1082
Failure code [CA1664] KDOC Malfunction 1083
Failure code [CA1691] Regeneration Ineffective 1086
Failure code [CA1695] Sensor 5 Supply Volt High Error .1089
Failure code [CA1696] Sensor 5 Supply Volt Low Error 1091
Failure code [CA1843] Crankcase Press Sens High Error .1093
Failure code [CA1844] Crankcase Press Sens Low Error 1095
Failure code [CA1879] KDPF Delta P Sensor High Error 1097
Failure code [CA1881] KDPF Delta P Sensor Low Error .1099
Failure code [CA1883] KDPF Delta P Sens In Range Error 1101
Failure code [CA1921] KDPF Soot Load High Error 1 .1104
Failure code [CA1922] KDPF Soot Load High Error 2 .1107
Failure code [CA1923] Dosing Fuel Valve 1 High Error 1112
Failure code [CA1924] Dosing Fuel Valve 1 Low Error .1114
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error 1116
Failure code [CA1927] Dosing Fuel Press Sens High Error .1118
Failure code [CA1928] Dosing Fuel Press Sens Low Error 1120
Failure code [CA1942] Crankcase Press Sens In Range Error .1122
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error .1123
Failure code [CA1977] Fuel Doser Open/Short Error .1126
Failure code [CA1993] KDPF Delta Pressure Low Error .1128
Failure code [CA2185] Throt Sensor Sup Volt High Error 1130
Failure code [CA2186] Throt Sensor Sup Volt Low Error .1132
Failure code [CA2249] Rail Press Very Low Error .1134
Failure code [CA2265] Fuel Feed Pump Open Error .1135
Failure code [CA2266] Fuel Feed Pump Short Error 1137
Failure code [CA2271] EGR Valve Pos Sens High Error .1139
Failure code [CA2272] EGR Valve Pos Sens Low Error 1141
Failure code [CA2349] EGR Valve Solenoid Open Error .1143
Failure code [CA2353] EGR Valve Solenoid Short Error 1145
Failure code [CA2357] EGR Valve Servo Error .1147
Failure code [CA2381] KVGT Pos Sens High Error 1148
Failure code [CA2382] KVGT Pos Sens Low Error .1150
Failure code [CA2383] KVGT Solenoid Open Error 1152
Failure code [CA2386] KVGT Solenoid Short Error .1154
Failure code [CA2387] KVGT Servo Error 1156
Failure code [CA2555] Grid Htr Relay Volt Low Error .1161
Failure code [CA2556] Grid Htr Relay Volt High Error 1163
Failure code [CA2637] KDOC Face Plugging 1165
Failure code [CA2639] Manual Stationary Regeneration Request 1167
Failure code [CA2732] Dosing Fuel Valve 2 High Error 1170
Failure code [CA2733] Dosing Fuel Valve 2 Low Error .1172
Failure code [CA2741] Dosing Fuel Valve Swap Error 1174
Failure code [CA2765] Inj Trim Data Error .1175
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error .1176
Failure code [CA2881] Dosing Fuel Pressure Low Error 1 1179
Failure code [CA3133] KDPF Outlet Press Sens High Error .1184
Failure code [CA3134] KDPF Outlet Press Sens Low Error 1186
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .1188
Failure code [CA3167] Fuel Doser Degradation 1191
Failure code [CA3251] KDOC Inlet Temp High Error 1194
Failure code [CA3253] KDOC Temp Error – Non Regeneration 1197
Failure code [CA3254] KDOC Outlet Temp High Error 1 .1200
Failure code [CA3255] KDPF Temp Error – Non Regeneration 1203
Failure code [CA3256] KDPF Outlet Temp High Error 1 .1207
Failure code [CA3311] KDOC Outlet Temp High Error 2 .1210
Failure code [CA3312] KDPF Outlet Temp High Error 2 .1213
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 1216
Failure code [CA3314] KDOC Inlet Temp Sens High Error .1219
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .1222
Failure code [CA3316] KDOC Outlet Temp Sens Low Error .1226
Failure code [CA3317] KDOC Outlet Temp Sens High Error 1229
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 1232
Failure code [CA3319] KDPF Outlet Temp Sens High Error 1235
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .1238
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 1240
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 1243
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error .1245
Failure code [D160KA] Disconnection of Backup Lamp Relay Output .1247
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output 1249
Failure code [D160KY] Hot Short of Backup Lamp Relay Output .1251
Failure code [D191KA] Disconnection of Neutral Output Relay .1253
Failure code [D191KB] Ground Fault of Neutral Output Relay 1255
Failure code [D191KY] Hot Short of Neutral Output Relay .1257
Failure code [D192KA] Disconnection of ECSS Solenoid 1259
Failure code [D192KB] Ground Fault of ECSS Solenoid .1261
Failure code [D192KY] Hot Short of ECSS Solenoid 1263
Failure code [D193KA] Disconnection of J/S Solenoid Cut Relay .1264
Failure code [D193KB] Ground Fault of J/S Solenoid Cut Relay 1266
Failure code [D193KY] Hot Short of J/S Solenoid Cut Relay .1268
Failure code [D193MC] Malfunction of J/S Solenoid Cut Relay .1270
Failure code [D19JKZ] Personal Code Relay Abnormality .1272
Failure code [D1E6KA] Disconnection of Parking Brake Relay 1274
Failure code [D1E6KB] Ground Fault of Parking Brake Relay .1276
Failure code [D1E6KY] Hot Short of Parking Brake Relay 1278
Failure code [D5ZHKA] Failure of Key SW C Signal 1280
Failure code [D5ZHKB] Key SW C Signal Short Circuit .1282
Failure code [D5ZHKZ] Failure of Key SW C Signal 1284
Failure code [D5ZHL6] Disconnection of Key SW C .1286
Failure code [D811MC] KOMTRAX Error .1288
Failure code [D862KA] GPS Antenna Open Circuit 1289
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .1290
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 1292
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .1294
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .1295
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 1297
Failure code [DAF0MB] Monitor ROM Abnormality .1298
Failure code [DAF0MC] Monitor Error .1299
Failure code [DAF3KK] Controller Power Source Low (MON) .1300
Failure code [DAF8KB] Camera Power Supply Short Circuit .1302
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 1303
Failure code [DAFGMC] GPS Module Error 1305
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) .1306
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 1308
Failure code [DAFQKR] CAN2 Discon (Monitor) .1310
Failure code [DAQ0KK] Controller Power Source Low (T/M) .1311
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) 1314
Failure code [DAQ0MC] T/M Con Error .1315
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .1316
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) .1318
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay .1321
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 1323
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) .1324
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) 1326
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 1328
Failure code [DAQRKR] CAN1 Discon (Transmission Con) 1329
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) .1330
Failure code [DAZ9KQ] A/C Model Selection Abnormality .1331
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1332
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1333
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1338
Failure code [DB90KK] Drop in BBC Controller Main Power Source 1343
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) 1346
Failure code [DB90MC] BBC Error .1347
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) .1348
Failure code [DB92KK] Solenoid Power Source Low (BBC) .1350
Failure code [DB95KX] Failure of 5 V Power Source 1 .1352
Failure code [DB96KX] Failure of 5 V Power Source 2 .1356
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) 1360
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) .1361
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) 1363
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .1365
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .1366
Failure code [DB9RMA] Inconsistency of Option Selection (BBC) .1367
Failure code [DBE5KX] Failure of 5V Power Source 1368
Failure code [DBE6KX] Failure of 24 V Power Source 1370
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW 1372
Failure code [DDA8KY] Hot Short of Throttle Lock Set SW .1376
Failure code [DDA9KY] Hot Short of Throttle Lock Resume SW 1378
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 1380
Failure code [DDB6L4] Neutral Signal Malfunction 1382
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch .1385
Failure code [DDE5KA] Failure of Emergency Steering Signal 1389
Failure code [DDK3KA] FNR SW Input Signal Disconnection .1391
Failure code [DDK3KB] FNR SW Input Signal Short Circuit .1396
Failure code [DDK4KA] J/S FNR Input Signal Disconnection 1400
Failure code [DDK4KB] J/S FNR Input Signal Short Circuit 1403
Failure code [DDK5L4] Failure of J/S Shift Up/Down SW .1405
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 1407
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit 1410
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .1412
Failure code [DDT0L4] Failure of Shift Mode Select SW .1416
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal .1420
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal .1424
Failure code [DDW9LD] Ground Fault of Kickdown Switch .1428
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW .1432
Failure code [DF10KA] Disconnection of Shift Lever Input 1436
Failure code [DF10KB] Ground Fault of Shift Lever Input .1439
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor .1441
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor 1443
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor 1445
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor 1447
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .1448
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor .1450
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor 1452
Failure code [DH21KA] Failure of Loader Pump Press. Sensor 1454
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit .1456
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit .1458
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor .1460
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor .1462
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. .1464
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor .1466
Failure code [DHT2L6] Failure of T/M Oil Filter Sensor Circuit 1468
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .1469
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor 1472
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor 1475
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit .1477
Failure code [DHT8ZG] Steering Oil Pressure Low .1479
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 1480
Failure code [DK55KA] Failure of FNR Lever Potentio .1482
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit .1484
Failure code [DK55L5] Failure of FNR Lever Potentio .1486
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) .1487
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) .1492
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .1497
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) 1504
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) 1510
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) .1515
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) .1520
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .1525
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) 1532
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) 1537
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) 1542
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) 1547
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree 1551
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) .1557
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) .1562
Failure code [DK5FKA] Failure of J/S Lever Potentio (Main) 1566
Failure code [DK5FKY] Hot Short of J/S Lever Potentio (Main) 1569
Failure code [DK5FL8] J/S Lever Potentio (Main & Sub) Disagree 1572
Failure code [DK5GKA] Failure of J/S Lever Potentio (Sub) .1576
Failure code [DK5GKY] Hot Short of J/S Lever Potentio (Sub) .1579
Failure code [DKA0KA] Failure of Boom Angle Sensor 1582
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit 1584
Failure code [DKA0L0] Boom Angle Sensor Dislocation .1586
Failure code [DKA1KA] Failure of Bucket Angle Sensor 1588
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit 1590
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor .1592
Failure code [DLF1LC] Failure of T/M Input Speed Sensor .1594
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 1596
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 1598
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) 1600
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) .1602
Failure code [DPQ1KR] LIN Discon (Switch Panel) .1604
Failure code [DPQ2KR] LIN Discon (LED Unit) .1607
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 1610
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 1613
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .1615
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. .1619
Failure code [DV00KB] Ground Fault of Buzzer Output .1623
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. 1625
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. .1626
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. 1627
Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve .1628
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve .1629
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) 1630
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) .1632
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) 1634
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) 1636
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) .1638
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) 1640
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) .1642
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) 1644
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) .1646
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) .1648
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) 1650
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) .1652
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid .1654
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. 1655
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. .1657
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid 1658
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid .1660
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid 1662
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) .1664
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) 1668
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) .1672
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) .1676
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) 1680
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) .1684
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. .1688
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. 1690
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. .1692
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid .1694
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid 1696
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid .1698
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) .1699
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 1701
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .1703
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 1705
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) .1707
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 1709
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 1711
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .1713
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 1715
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 1717
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) .1718
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 1720
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 1722
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) .1724
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 1726
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) 1728
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) .1730
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) 1732
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) 1734
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) .1736
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) 1738
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) .1740
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 1742
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .1744
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) .1746
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 1748
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) .1750
Failure code [DXHLKA] Disconnection of J/S Right EPC Solenoid .1752
Failure code [DXHLKB] Ground Fault of J/S Right EPC Solenoid 1754
Failure code [DXHLKY] Hot Short of J/S Right EPC Solenoid .1756
Failure code [DXHMKA] Disconnection of J/S Left EPC Solenoid 1758
Failure code [DXHMKB] Ground Fault of J/S Left EPC Solenoid .1760
Failure code [DXHMKY] Hot Short of J/S Left EPC Solenoid 1762
Failure code [LA00L3] Failure of Fan Reverse 1764
Troubleshooting of electrical system (E-mode) .1765
E-1 Engine does not start (Engine does not crank) .1765
E-2 Manual preheating system does not work 1772
E-3 Automatic preheating system does not work .1775
E-4 While preheating is working, preheating monitor does not light up .1777
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing 1779
E-6 LCD unit on machine monitor displays nothing 1782
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) .1784
E-8 LCD on machine monitor does not display properly 1786
E-9 Meter unit display on machine monitor is abnormal .1788
E-10 Night lighting lamp of meter unit on machine monitor is abnormal .1791
E-11 Caution LED on machine monitor is abnormal .1794
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly .1796
E-13 Two switches operation of switch panel on machine monitor does not function 1798
E-14 Switch panel buzzer of machine monitor is abnormal .1801
E-15 Rearview monitor does not light up or backlight flickers .1803
E-16 Rearview monitor images are not displayed clearly 1806
E-17 Rearview monitor brightness cannot be adjusted .1809
E-18 Night lighting lamp of rearview monitor is abnormal 1812
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly .1814
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position .1815
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light 1819
E-22 Air cleaner clogging indicator lamp does not light .1821
E-23 Radiator coolant level caution lamp does not light .1822
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light 1824
E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light 1826
E-26 Fuel level gauge does not indicate correct level .1827
E-27 Seat belt caution lamp indication is abnormal 1829
E-28 Horn does not sound 1830
E-29 Horn does not stop sounding 1832
E-30 Alarm buzzer does not sound 1833
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding 1834
E-32 Kickdown does not work when kickdown switch is turned ON .1835
E-33 The hold switch does not work when it is pressed .1837
E-34 Transmission is always shifted to Neutral, or the brake drags when parking brake applies and FR drive is selected 1839
E-35 Transmission cut-off mode is not selected or not released 1842
E-36 Transmission cut-off setting cannot be released 1844
E-37 FNR switch mode is not selected or not released 1846
E-38 When operating engine mode selector switch, engine mode selector function does not operate properly 1848
E-39 Flow of loader pump does not increase from the minimum rate 1850
E-40 ECSS function cannot be selected or cannot be released .1851
E-41 None of headlamp, clearance lamp, and tail lamp lights .1853
E-42 Clearance lamp and tail lamp do not light up or go out .1855
E-43 Both High and Low beams of headlamp do not light up or go out 1858
E-44 Low beam of headlamp does not light up or go out .1862
E-45 High beam of headlamp does not light up or go out 1864
E-46 Front working lamp does not light up or go out .1866
E-47 Rear working lamp does not light up or go out 1869
E-48 All of turn signal lamps and hazard lamps do not light up or go out 1872
E-49 Turn signal lamps do not light up or go out 1875
E-50 Hazard lamp does not light up or go out 1878
E-51 Brake lamp does not light up or stays lighted 1881
E-52 Backup lamp does not light or continues to light .1884
E-53 Backup buzzer does not sound or continues to sound .1887
E-54 Front wiper does not operate .1889
E-55 Rear wiper does not operate 1892
E-56 Window washer does not operate .1895
E-57 Fuel feed pump does not operate or stop automatically 1898
E-58 KOMTRAX system does not operate properly .1900
Troubleshooting of hydraulic and mechanical system (H-mode) .1902
Information described in troubleshooting table (H-mode) .1902
System chart of hydraulic and mechanical systems 1903
Failure mode and cause table 1907
H-1 Machine does not start 1916
H-2 Torque converter lockup clutch is not disengaged (engine stalls) 1919
H-3 Torque converter lockup clutch is not engaged .1920
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift .1921
H-5 Large shock is made when machine starts or gear is shifted 1924
H-6 Machine starts or gear speed shifts with long time lag 1926
H-7 Torque converter oil temperature is high 1928
H-8 Machine does not turn .1930
H-9 Turning response is poor 1934
H-10 Steering wheel is heavy to turn 1938
H-11 Machine sways or large shocks are made while machine turns .1939
H-12 Turning radius differs between right and left turns 1943
H-13 Wheel brakes do not work or are weak .1944
H-14 Wheel brakes are not released or drag 1946
H-15 Parking brake does not work or it is weak 1947
H-16 Parking brake is not released or drags (including emergency release system) 1948
H-17 Boom does not rise .1949
H-18 Boom moves slow or boom lacks lifting force 1951
H-19 Rising boom slows down at certain height .1953
H-20 Lift cylinders do not serve to hold bucket on ground .1954
H-21 Hydraulic drift of boom is large .1955
H-22 Boom moves up and down during operation 1956
H-23 Bucket does not tilt back 1957
H-24 Bucket moves slow or bucket lacks tilt-back force 1959
H-25 Bucket decelerates during tilt-back operation 1961
H-26 Bucket cylinder does not hold bucket on ground .1962
H-27 Hydraulic drift of bucket is large .1963
H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) 1964
H-29 Boom and bucket control levers do not move smoothly and are heavy to move 1965
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall .1966
H-31 Large shocks are made when work equipment starts to move and stops .1967
H-32 When certain work equipment stalls hydraulically, other work equipment moves .1969
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces .1970
H-34 Fan speed is abnormal (too high or low, or fan does not rotate) 1971
H-35 Unusual noise is heard from around fan .1972
Troubleshooting of engine (S-mode) 1973
Information mentioned in troubleshooting table (S mode) .1973
S-1 When starting switch is turned to START position, engine is not cranked .1974
S-2 The engine cranks but exhaust smoke does not come out .1975
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) 1976
S-4 Engine startability is poor .1977
S-5 Engine does not pick-up smoothly 1979
S-6 Engine stops during operation .1981
S-7 Engine runs rough or is unstable 1983
S-8 Engine lacks power 1984
S-9 KDPF gets clogged in a short time .1986
S-10 Engine oil consumption is excessive 1988
S-11 Engine oil becomes contaminated early 1989
S-12 Fuel consumption is excessive 1990
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .1991
S-14 Oil pressure drops .1992
S-15 Fuel mixes into engine oil .1993
S-16 Water mixes into engine oil (milky) 1994
S-17 Coolant temperature rises too high (overheating) .1995
S-18 Unusual noise is heard .1996
S-19 Vibration is excessive .1997
S-20 Air cannot be bled from fuel circuit .1998
S-21 Active regeneration is executed frequently .1999
S-22 Active regeneration takes a long time 2000
S-23 White smoke is exhausted during active regeneration 2001
50 Disassembly and assembly .2003
Table of contents .2004
Precautions before work 2006
Related information on disassembly and assembly .2008
How to read this manual .2008
Coating materials list 2010
Special tools list 2014
Sketches of special tools .2020
Engine and cooling system .2028
Removal and installation of supply pump assembly 2028
Removal and installation of injector assembly .2034
Removal and installation of cylinder head assembly 2054
Removal and installation of engine hood assembly 2076
Removal and installation of radiator core assembly 2080
Removal and installation of aftercooler .2083
Removal and installation of hydraulic oil cooler 2086
Removal and installation of power train oil cooler assembly .2090
Removal and installation of engine assembly .2092
Removal and installation of engine front oil seal .2099
Removal and installation of engine rear oil seal 2102
Removal and installation of cooling fan and fan motor assembly 2107
Removal and installation of KDPF assembly .2109
Disassembly and assembly of KDPF assembly .2112
Removal and installation of KCCV assembly .2120
Removal and installation of KVGT assembly .2122
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .2126
Removal and installation of air cleaner assembly 2130
Removal and installation of air conditioner compressor assembly .2132
Removal and installation of air conditioner condenser assembly 2134
Removal and installation of belt for alternator and air conditioner compressor 2136
Removal and installation of fuel tank assembly 2138
Power train .2140
Removal and installation of power train unit assembly .2140
Disconnection and connection of power train unit assembly .2145
Disassembly and assembly of input transfer assembly .2149
Disassembly and assembly of torque converter assembly .2155
Disassembly and assembly of transmission assembly .2168
Disassembly and assembly of transfer and parking brake assembly .2196
Removal and installation of front differential assembly .2213
Disassembly and assembly of differential assembly (with LSD) 2215
Disassembly and assembly of differential assembly (without LSD) .2229
Removal and installation of front axle assembly .2241
Removal and installation of rear axle assembly 2243
Disassembly and assembly of final drive assembly (front and rear) .2245
Steering system .2251
Removal and installation of steering valve assembly .2251
Brake system 2253
Removal and installation of brake assembly (front and rear) .2253
Disassembly and assembly of brake assembly (front and rear) .2257
Disassembly and assembly of slack adjuster assembly .2264
Disassembly and assembly of brake accumulator charge valve assembly .2265
Undercarriage and frame .2265
Removal and installation of center hinge pin 2265
Removal and installation of large counterweight assembly 2272
Removal and installation of small counterweight assembly 2274
Hydraulic system 2276
Removal and installation of hydraulic tank assembly .2276
Removal and installation of work equipment pump assembly 2279
Removal and installation of steering and power train pump assembly 2281
Removal and installation of cooling fan pump assembly .2283
Removal and installation of work equipment control valve assembly .2285
Disassembly and assembly of work equipment control valve assembly .2288
Removal and installation of diverter valve assembly .2291
Disassembly and assembly of steering cylinder assembly 2293
Disassembly and assembly of work equipment cylinder assembly 2296
Work equipment 2301
Removal and installation of work equipment assembly .2301
Cab and its attachments .2305
Removal and installation of operator’s cab assembly .2305
Removal and installation of operator’s cab glass (stuck window glass) .2310
Removal and installation of operator’s seat assembly 2318
Removal and installation of seat belt .2320
Removal and installation of air conditioner unit assembly .2321
Electrical system .2326
Removal and installation of machine monitor assembly 2326
Removal and installation of work equipment controller assembly 2327
Removal and installation of rear view monitor assembly 2329
Removal and installation of engine controller assembly 2330
Removal and installation of transmission controller assembly 2332
Removal and installation of monitor controller assembly .2333
Removal and installation of mass air flow and temperature sensor 2335
Removal and installation of KOMTRAX terminal assembly .2336
60 Maintenance standard .2337
Table of contents .2338
Engine and cooling system .2339
Engine mount and transmission mount .2339
Joint .2341
Cooling fan pump 2342
Servo valve .2344
Cooling fan motor .2345
Power train .2347
Drive shaft .2347
Torque converter 2348
Torque converter regulator valve 2352
Transmission 2353
Transmission control valve 2360
Forward and reverse clutch ECMV and gear speed clutch ECMV 2361
Lockup clutch ECMV 2362
Main relief valve, torque converter relief valve, and main flow selector valve 2363
Center support 2365
Lubricating oil relief valve 2366
Axle 2367
Differential 2369
Final drive .2375
Steering system .2377
Steering column .2377
Steering pump .2378
Steering control valve 2382
Steering cylinder .2383
Diverter valve 2385
Emergency steering pump .2386
Brake system 2387
Charge valve 2387
Brake valve .2389
Slack adjuster 2390
Accumulator (for brake) .2391
Brake .2392
Parking brake .2394
Parking brake solenoid valve 2396
Undercarriage and frame .2397
Axle mount 2397
Center hinge pin 2400
Hydraulic system 2402
Hydraulic tank 2402
Double type gear pump .2403
Work equipment pump .2405
Control valve .2407
Accumulator charge valve 2416
Work equipment 2417
Work equipment linkage 2417
Bucket 2420
Bucket positioner and boom positioner .2422
Work equipment cylinder .2423
80 Appendix .2425
Table of contents .2426
Precautions before work 2427
Air conditioner components 2429
Precautions for refrigerant .2429
Air conditioner component .2430
Configuration and function of refrigeration cycle .2432
Outline of refrigeration cycle 2433
Air conditioner unit 2435
Dual pressure switch 2440
Air conditioner controller 2441
Compressor 2442
Condenser .2443
Receiver drier 2444
Sunlight sensor .2446
Outer temperature sensor (outside air temperature sensor) .2447
Procedure for testing and troubleshooting .2448
Circuit diagram and arrangement of connector pins .2450
Parts and connectors layout .2453
Testing with self-diagnosis function 2458
Testing temperature control system 2461
Testing vent (mode) changeover 2463
Testing FRESH/RECIRC air changeover .2465
Check evaporator temperature sensor .2467
Testing relays 2469
Troubleshooting chart 1 .2471
Troubleshooting chart 2 .2472
Information in troubleshooting table 2474
Failure code list related to air conditioner 2475
Failure code [879AKA] A/C Inner Sensor Open Circuit .2476
Failure code [879AKB] A/C Inner Sensor Short Circuit 2478
Failure code [879BKA] A/C Outer Sensor Open Circuit .2480
Failure code [879BKB] A/C Outer Sensor Short Circuit 2482
Failure code [879CKA] Ventilating Sensor Open Circuit .2484
Failure code [879CKB] Ventilating Sensor Short Circuit 2486
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .2488
Failure code [879EMC] Ventilation Damper Abnormality 2490
Failure code [879FMC] Air Mix Damper Abnormality 2493
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 2496
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) .2499
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2502
A-4 Troubleshooting for FRESH/RECIRC air changeover .2505
Troubleshooting with gauge pressure .2507
Connection of service tool 2510
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit .2512
Handling of compressor oil 2514
90 Diagrams and drawings 2517
Table of contents .2518
Hydraulic circuit diagram .2519
Symbols in hydraulic circuit diagram 2519
Power train hydraulic circuit diagram 2523
Brake hydraulic circuit diagram 2525
Hydraulic circuit diagram 2527
Electric circuit diagram 2531
Symbols in electric circuit diagram .2531
Electrical circuit diagram .2535
Electrical circuit diagram (1/13) 2535
Electrical circuit diagram (2/13) 2537
Electrical circuit diagram (3/13) 2539
Electrical circuit diagram (4/13) 2541
Electrical circuit diagram (5/13) 2543
Electrical circuit diagram (6/13) 2545
Electrical circuit diagram (7/13) 2547
Electrical circuit diagram (8/13) 2549
Electrical circuit diagram (9/13) 2551
Electrical circuit diagram (10/13) .2553
Electrical circuit diagram (11/13) .2555
Electrical circuit diagram (12/13) .2557
Electrical circuit diagram (13/13) .2559
Electrical circuit diagram of floor 2561
Electrical circuit diagram of floor (1/7) (EU specification) .2561
Electrical circuit diagram of floor (2/7) (EU specification) .2563
Electrical circuit diagram of floor (3/7) (EU specification) .2565
Electrical circuit diagram of floor (4/7) (EU specification) .2567
Electrical circuit diagram of floor (5/7) (EU specification) .2569
Electrical circuit diagram of floor (6/7) (EU specification) .2571
Electrical circuit diagram of floor (7/7) (EU specification) .2573
INDEX 2575

DESCRIPTION:

Komatsu WA500-7 Wheel Loader Shop Manual SEN05693-16 –  PDF DOWNLOAD

• SERIAL NUMBERS 10001 and up

G.B 27/12/24