Komatsu WA270-7 Wheel Loader Shop Manual SEN06255-07 – PDF DOWNLOAD

Komatsu WA270-7 Wheel Loader Shop Manual SEN06255-07 – PDF DOWNLOAD

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Komatsu WA270-7 Wheel Loader Shop Manual SEN06255-07 – PDF DOWNLOAD

Language : English
Pages : 2080
Downloadable : Yes
File Type : PDF
Size: 61.4 MB

DESCRIPTION:

Komatsu WA270-7 Wheel Loader Shop Manual SEN06255-07 – PDF DOWNLOAD

SERIAL NUMBERS 80001 and up

Foreword, safety and general information 
Important safety notice 
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol markkis used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.

Safety points
• Good arrangement
• Correct work clothes
• Observance of work standard
• Practice of making and checking signals
• Prohibition of operation and handling by
unlicensed workers
• Safety check before starting work
• Wearing protective goggles (for cleaning or
grinding work)
• Wearing shielding goggles and protectors (for
welding work)
• Good physical condition and preparation
• Precautions against work which you are not used to or you are used to too much

General precautions:

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer.Always wear the protective eyeglasses when grinding parts with a grinder, etc.• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.• Only qualified workers must perform the work and operation which require license or qualification.• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.• Before starting work, warm up your body thoroughly to start work under good condition.• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

How to read the shop manual :
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for “Machine part” and “Engine part”. For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu WA270-7 Wheel Loader Shop Manual SEN06255-07 – PDF DOWNLOAD

Index (ALL-0310-001-A-00-A)
00 Index and foreword 00-1
Index 00-2
Foreword, safety and general information 00-17
Important safety notice 00-17
How to read the shop manual 00-24
Explanation of terms for maintenance standard 00-26
Handling equipment of fuel system devices 00-28
Handling of intake system parts 00-29
Handling of hydraulic equipment 00-30
Method of disconnecting and connecting of push-pull type coupler 00-32
Handling of electrical equipment 00-35
How to read electric wire code 00-43
Precautions when performing operation 00-46
Practical use of KOMTRAX 00-51
Standard tightening torque table 00-52
List of abbreviation 00-58
Conversion table 00-63
01 Specification 01-1
Table of contents 01-2
Specifications 01-3
Specification drawing 01-3
Specifications 01-7
Weight table 01-17
Table of fuel, coolant, and lubricants 01-21
10 Structure and function 10-1
Table of contents 10-2
Engine and cooling system 10-4
Engine related parts 10-4
KVGT 10-6
EGR system piping drawing 10-13
EGR system circuit diagram 10-15
EGR valve 10-17
EGR cooler 10-19
KCCV layout drawing 10-20
KCCV ventilator 10-22
KDPF 10-24
Cooling system 10-28
Cooling fan motor 10-30
Power train 10-41
Power train system 10-41
Layout of power train parts 10-43
Damper 10-44
HST pump 10-45
HST motor1 10-58
HST motor2 10-60
Transfer 10-65
Clutch solenoid valve 10-72
Drive shaft 10-74
Axle 10-75
Differential 10-77
Torque proportional differential 10-81
Limited slip differential 10-83
Final drive 10-88
Steering system 10-91
Layout of steering devices 10-91
Steering column 10-92
Priority valve 10-93
Cushion valve 10-97
00-2 WA270-7
00 Index and foreword
Index
Emergency steering valve 10-98
Orbitrol valve 10-101
2way restrictor valve 10-107
Brake system 10-108
Layout of brake parts 10-108
Brake accumulator charge valve 10-110
Brake valve 10-115
Brake accumulator 10-119
Slack adjuster 10-120
Brake 10-122
Parking brake control 10-125
Parking brake 10-126
Parking brake solenoid valve 10-127
Undercarriage and frame 10-129
Axle mount 10-129
Center hinge pin 10-131
Tire 10-132
Hydraulic system 10-134
Hydraulic component layout 10-134
Work equipment control 10-136
Hydraulic tank 10-137
Double type gear pump 10-140
Steering and work equipment pump 10-141
Control valve 10-153
CLSS 10-163
Hydraulic circuit diagram and names of valves 10-167
Self-pressure reducing valve 10-180
Work equipment PPC valve 10-185
Work equipment lock solenoid valve 10-193
PPC circuit accumulator 10-194
ECSS accumulator 10-195
Work equipment 10-196
Work equipment linkage 10-196
Bucket 10-197
Cab and its attachments 10-198
ROPS cab 10-198
Cab mount 10-200
Electrical system 10-201
Engine control system 10-201
Preheating system 10-204
Engine output limit function 10-206
Automatic warm-up function 10-207
Parking brake control system 10-208
System operating lamp function 10-212
Battery disconnect switch function 10-213
HSTcontroller system 10-215
Machine monitor system 10-255
Rearview monitor system 10-276
KOMTRAX system 10-279
System component parts 10-282
Sensor 10-305
20 Standard value tables 20-1
Table of contents 20-2
Standard service value table 20-3
Standard value table for engine 20-3
Standard value table for machine 20-5
Standard value table for electrical system 20-17
30 Testing and adjusting 30-1
Table of contents 30-2
WA270-7 00-3
00 Index and foreword
Index
Related information on testing and adjusting 30-4
Tools for testing and adjusting 30-4
Sketch of tools for testing and adjusting 30-10
Engine and cooling system 30-11
Testing engine speed 30-11
Testing boost pressure 30-12
Testing exhaust gas temperature 30-14
Testing exhaust gas color 30-15
Testing and adjusting valve clearance 30-17
Testing compression pressure 30-19
Testing blowby pressure 30-23
Testing engine oil pressure 30-24
Testing EGR valve and KVGToil pressures 30-25
Testing fuel pressure 30-26
Testing fuel discharge, return and leakage 30-30
Bleeding air from fuel system 30-35
Testing fuel circuit for leakage 30-37
Handling cylinder cutout mode operation 30-38
Handling no-injection cranking operation 30-39
Testing of KDPF and muffler stack for looseness and damage 30-40
Testing of installed condition of cylinder heads and manifolds 30-41
Testing engine piping for damage and looseness 30-42
Testing and adjusting air conditioner compressor belt tension 30-43
Check alternator belt, replace 30-44
Check auto-tensioner, replace 30-46
Writing compensation amount for soot accumulation caused by ash on engine
controller 30-48
Power train 30-50
Testing oil leakage from axle final drive 30-50
Testing drive shaft for looseness, backlash, and damage 30-51
Testing accelerator pedal 30-52
Testing and adjusting HSToil pressure 30-53
Testing transfer clutch control pressure 30-56
Steering system 30-57
Testing directional lever 30-57
Testing steering wheel 30-58
Testing work equipment control lever 30-60
Testing and adjusting steering circuit oil pressure 30-62
Bleeding air from steering cylinder circuit 30-64
Brake system 30-65
Testing brake pedal 30-65
Testing braking performance 30-66
Testing and adjusting of accumulator charge pressure 30-67
Testing wheel brake oil pressure 30-69
Testing lowering of wheel brake pressure 30-70
Testing wear of wheel brake disc 30-72
Bleeding air from wheel brake circuit 30-73
Releasing remaining pressure in brake accumulator circuit 30-74
Testing parking brake performance 30-75
Testing wear of parking brake disc 30-76
Testing parking brake release pressure 30-77
Method of releasing parking brake manually 30-78
Hydraulic system 30-79
Testing cooling fan speed 30-79
Testing cooling fan pump circuit oil pressure 30-80
Bleeding air from hydraulic fan circuit 30-82
Testing and adjusting work equipment PPC oil pressure 30-83
Testing and adjusting work equipment oil pressure 30-85
Bleeding air from work equipment circuit 30-89
00-4 WA270-7
00 Index and foreword
Index
Releasing remaining pressure from work equipment circuit 30-90
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with
nitrogen gas 30-92
Work equipment 30-96
Testing and adjusting bucket positioner and bucket proximity switch 30-96
Testing and adjusting boom position detection lever 30-98
Electrical system 30-99
Adjusting replaced, reassembled or added sensor, controller, etc with machine
monitor 30-99
Special functions of machine monitor 30-100
Adjusting rearview camera angle 30-178
Handling voltage circuit of engine controller 30-179
Handling battery disconnect switch 30-180
Testing diodes 30-181
Pm clinic 30-182
Pm Clinic service 30-182
Check sheet 30-183
40 Troubleshooting 40-1
Table of contents 40-2
Related information on troubleshooting 40-11
Troubleshooting points 40-11
Sequence of events in troubleshooting 40-13
Checks before troubleshooting 40-15
Inspection procedure before troubleshooting 40-17
Preparation for troubleshooting of electrical system 40-34
Classification and procedures for troubleshooting 40-40
Symptom and troubleshooting numbers 40-43
Information described in troubleshooting table 40-46
Procedure for troubleshooting wiring harness of pressure sensor system for open
circuit 40-48
Connector list and layout 40-51
Connector contact identification 40-65
T-branch box and T-branch adapter table 40-104
Fuse location table 40-109
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 40-112
Precautions when performing troubleshooting of machine monitor 40-115
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit 40-117
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors) 40-122
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) 40-123
Failure codes table 40-124
Troubleshooting by failure code (Display of code) 40-136
Failure code [2F00MA] Failure of Parking Brake Circuit 40-136
Failure code [2F00MB] Malfunction of Parking Brake 40-139
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 40-141
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 40-143
Failure code [6091NX] HST Oil Filter Clogging 40-145
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol 40-147
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol 40-149
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol 40-151
Failure code [879AKA] A/C Inner Sensor Open Circuit 40-153
Failure code [879AKB] A/C Inner Sensor Short Circuit 40-154
Failure code [879BKA] A/C Outer Sensor Open Circuit 40-155
Failure code [879BKB] A/C Outer Sensor Short Circuit 40-156
Failure code [879CKA] Ventilating Sensor Open Circuit 40-157
Failure code [879CKB] Ventilating Sensor Short Circuit 40-158
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 40-159
WA270-7 00-5
00 Index and foreword
Index
Failure code [879EMC] Ventilation Damper Abnormality 40-160
Failure code [879FMC] Air Mix Damper Abnormality 40-161
Failure code [989L00] Engine Controller Lock Caution 1 40-162
Failure code [989M00] Engine Controller Lock Caution 2 40-163
Failure code [989N00] Engine Controller Lock Caution 3 40-164
Failure code [A1U0N3] HC Desorb Request 1 40-165
Failure code [A1U0N4] HC Desorb Request 2 40-167
Failure code [AB00KE] Charge Voltage Low 40-169
Failure code [AB00KY] Hot Short of Alternator R Terminal 40-170
Failure code [B@BAZG] Eng Oil Press Low 40-171
Failure code [B@BCNS] Eng Water Overheat 40-172
Failure code [B@BCZK] Eng Water Level Low 40-173
Failure code [B@CRNS] HST Oil Temp Overheat 40-175
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 40-176
Failure code [CA122] Chg Air Press Sensor High Error 40-177
Failure code [CA123] Chg Air Press Sensor Low Error 40-179
Failure code [CA131] Throttle Sensor High Error 40-181
Failure code [CA132] Throttle Sensor Low Error 40-183
Failure code [CA144] Coolant Temp Sens High Error 40-185
Failure code [CA145] Coolant Temp Sens Low Error 40-187
Failure code [CA153] Chg Air Temp Sensor High Error 40-189
Failure code [CA154] Chg Air Temp Sensor Low Error 40-191
Failure code [CA187] Sensor 2 Supply Volt Low Error 40-193
Failure code [CA221] Ambient Press Sensor High Error 40-195
Failure code [CA222] Ambient Press Sensor Low Error 40-197
Failure code [CA227] Sensor 2 Supply Volt High Error 40-199
Failure code [CA234] Eng Overspeed 40-200
Failure code [CA238] Ne Speed Sensor Supply Volt Error 40-201
Failure code [CA239] Ne Speed Sens Supply Volt High Error 40-202
Failure code [CA271] IMV/PCV1 Short Error 40-203
Failure code [CA272] IMV/PCV1 Open Error 40-205
Failure code [CA295] Ambient Press Sens In Range Error 40-207
Failure code [CA322] Inj #1(L#1) Open/Short Error 40-208
Failure code [CA323] Inj #5(L#5) Open/Short Error 40-210
Failure code [CA324] Inj #3(L#3) Open/Short Error 40-212
Failure code [CA325] Inj #6(L#6) Open/Short Error 40-214
Failure code [CA331] Inj #2(L#2) Open/Short Error 40-216
Failure code [CA332] Inj #4(L#4) Open/Short Error 40-218
Failure code [CA343] ECM Critical Internal Failure 40-220
Failure code [CA351] Injectors Drive Circuit Error 40-221
Failure code [CA352] Sensor 1 Supply Volt Low Error 40-222
Failure code [CA356] Mass Air Flow Sensor High Error 40-224
Failure code [CA357] Mass Air Flow Sensor Low Error 40-226
Failure code [CA386] Sensor 1 Supply Volt High Error 40-228
Failure code [CA428] Water in Fuel Sensor High Error 40-229
Failure code [CA429] Water in Fuel Sensor Low Error 40-231
Failure code [CA431] Idle Validation Sw Error 40-233
Failure code [CA432] Idle Validation Process Error 40-236
Failure code [CA435] Eng Oil Press Sw Error 40-239
Failure code [CA441] Battery Voltage Low Error 40-240
Failure code [CA442] Battery Voltage High Error 40-242
Failure code [CA449] Rail Press Very High Error 40-243
Failure code [CA451] Rail Press Sensor High Error 40-244
Failure code [CA452] Rail Press Sensor Low Error 40-246
Failure code [CA488] Chg Air Temp High Torque Derate 40-248
Failure code [CA515] Rail Press Sens Sup Volt High Error 40-249
Failure code [CA516] Rail Press Sens Sup Volt Low Error 40-251
Failure code [CA553] Rail Press High Error 40-253
Failure code [CA555] Crankcase Press High Error 1 40-254
00-6 WA270-7
00 Index and foreword
Index
Failure code [CA556] Crankcase Press High Error 2 40-255
Failure code [CA559] Rail Press Low Error 40-256
Failure code [CA595] Turbo Speed High Error 2 40-258
Failure code [CA687] Turbo Speed Low Error 40-259
Failure code [CA689] Eng Ne Speed Sensor Error 40-261
Failure code [CA691] Intake Air Temp Sens High Error 40-263
Failure code [CA692] Intake Air Temp Sens Low Error 40-265
Failure code [CA697] ECM Internal Temp Sensor High Error 40-267
Failure code [CA698] ECM Int Temp Sensor Low Error 40-268
Failure code [CA731] Eng Bkup Speed Sens Phase Error 40-269
Failure code [CA778] Eng Bkup Speed Sensor Error 40-271
Failure code [CA1117] Persistent Data Lost Error 40-276
Failure code [CA1664] KDOC Malfunction 40-277
Failure code [CA1691] Regeneration Ineffective 40-280
Failure code [CA1695] Sensor 5 Supply Volt High Error 40-283
Failure code [CA1696] Sensor 5 Supply Volt Low Error 40-284
Failure code [CA1843] Crankcase Press Sens High Error 40-286
Failure code [CA1844] Crankcase Press Sens Low Error 40-288
Failure code [CA1879] KDPF Delta P Sensor High Error 40-290
Failure code [CA1881] KDPF Delta P Sensor Low Error 40-292
Failure code [CA1883] KDPF Delta P Sens In Range Error 40-294
Failure code [CA1921] KDPF Soot Load High Error 1 40-298
Failure code [CA1922] KDPF Soot Load High Error 2 40-301
Failure code [CA1942] Crankcase Press Sens In Range Error 40-306
Failure code [CA1993] KDPF Delta Pressure Low Error 40-307
Failure code [CA2185] Throt Sensor Sup Volt High Error 40-310
Failure code [CA2186] Throt Sensor Sup Volt Low Error 40-312
Failure code [CA2249] Rail Press Very Low Error 40-314
Failure code [CA2271] EGR Valve Pos Sens High Error 40-315
Failure code [CA2272] EGR Valve Pos Sens Low Error 40-317
Failure code [CA2288] Turbo Speed High Error 1 40-320
Failure code [CA2311] IMV Solenoid Error 40-321
Failure code [CA2349] EGR Valve Solenoid Open Error 40-322
Failure code [CA2353] EGR Valve Solenoid Short Error 40-324
Failure code [CA2357] EGR Valve Servo Error 40-326
Failure code [CA2373] Exhaust Manifold Press Sens High error 40-327
Failure code [CA2374] Exhaust Manifold Press Sens Low error 40-329
Failure code [CA2375] EGR Orifice Temp Sens High Error 40-331
Failure code [CA2376] EGR Orifice Temp Sens Low Error 40-333
Failure code [CA2381] KVGT Pos Sens High Error 40-335
Failure code [CA2382] KVGT Pos Sens Low Error 40-337
Failure code [CA2383] KVGT Solenoid Open Error 40-340
Failure code [CA2386] KVGT Solenoid Short Error 40-342
Failure code [CA2387] KVGT Servo Error 40-344
Failure code [CA2554] Exh Manifold Press Sens In Range Error 40-345
Failure code [CA2555] Grid Htr Relay Volt Low Error 40-346
Failure code [CA2556] Grid Htr Relay Volt High Error 40-348
Failure code [CA2637] KDOC Face Plugging 40-350
Failure code [CA2639] Manual Stationary Regeneration Request 40-352
Failure code [CA2961] EGR Orifice Temp High Error 1 40-355
Failure code [CA2973] Chg Air Press Sensor In Range Error 40-356
Failure code [CA3133] KDPF Outlet Press Sens High Error 40-357
Failure code [CA3134] KDPF Outlet Press Sens Low Error 40-359
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 40-361
Failure code [CA3251] KDOC Inlet Temp High Error 40-365
Failure code [CA3253] KDOC Temp Error – Non Regeneration 40-368
Failure code [CA3254] KDOC Outlet Temp High Error 1 40-372
Failure code [CA3255] KDPF Temp Error – Non Regeneration 40-375
Failure code [CA3256] KDPF Outlet Temp High Error 1 40-379
WA270-7 00-7
00 Index and foreword
Index
Failure code [CA3311] KDOC Outlet Temp High Error 2 40-382
Failure code [CA3312] KDPF Outlet Temp High Error 2 40-386
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 40-390
Failure code [CA3314] KDOC Inlet Temp Sens High Error 40-393
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 40-396
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 40-400
Failure code [CA3317] KDOC Outlet Temp Sens High Error 40-403
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 40-406
Failure code [CA3319] KDPF Outlet Temp Sens High Error 40-410
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 40-413
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 40-416
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 40-420
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 40-422
Failure code [CA3741] Rail Press Valve Trip Error 40-424
Failure code [D110L4] Disconnection of Battery Relay Signal 40-425
Failure code [D160KA] Disconnection of Backup Lamp Relay Output 40-427
Failure code [D160KY] Hot Short of Backup Lamp Relay Output 40-429
Failure code [D191KA] Disconnection of Neutral Output Relay 40-431
Failure code [D191KB] Ground Fault of Neutral Output Relay 40-433
Failure code [D191KY] Hot Short of Neutral Output Relay 40-435
Failure code [D192KA] Disconnection of ECSS Solenoid 40-437
Failure code [D192KB] Ground Fault of ECSS Solenoid 40-439
Failure code [D192KY] Hot Short of ECSS Solenoid 40-440
Failure code [D19JKZ] Personal Code Relay Abnormality 40-441
Failure code [D1B0KA] Disconnection of HST Safety Relay 40-443
Failure code [D1B0KB] Ground Fault of HST Safety Relay 40-445
Failure code [D1B0KY] Hot Short of HST Safety Relay 40-447
Failure code [D1B0MC] Malfunction of HST Safety Relay 40-449
Failure code [D1E6KA] Disconnection of Parking Brake Relay 40-450
Failure code [D1E6KB] Ground Fault of Parking Brake Relay 40-452
Failure code [D1E6KY] Hot Short of Parking Brake Relay 40-454
Failure code [D5ZHKA] Failure of Key SW C Signal 40-456
Failure code [D5ZHKB] Key SW C Signal Short Circuit 40-458
Failure code [D5ZHL6] Disconnection of Key SW C 40-460
Failure code [D811MC] KOMTRAX Error 40-461
Failure code [D862KA] GPS Antenna Open Circuit 40-462
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 40-463
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 40-465
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 40-467
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 40-468
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 40-470
Failure code [DAF0MB] Monitor ROM Abnormality 40-471
Failure code [DAF0MC] Monitor Error 40-472
Failure code [DAF3KK] Controller Power Source Low (MON) 40-473
Failure code [DAF8KB] Camera Power Supply Short Circuit 40-475
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 40-476
Failure code [DAFGMC] GPS Module Error 40-477
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) 40-478
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 40-480
Failure code [DAFQKR] CAN2 Discon (Monitor) 40-482
Failure code [DAJ0KK] Controller Power Source Low (HST) 40-483
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) 40-486
Failure code [DAJ0MC] HST Con Error 40-487
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) 40-488
Failure code [DAJ2KK] Solenoid Power Source Low (HST) 40-490
Failure code [DAJ4KB] Ground Fault of Sol Self-Holding Relay 40-493
Failure code [DAJ4KZ] Failure of Sol Self-Holding Relay 40-495
Failure code [DAJ5KX] Failure of 5V Power Source 0 40-497
Failure code [DAJ6KX] Failure of 5V Power Source 1 40-499
00-8 WA270-7
00 Index and foreword
Index
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) 40-501
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) 40-502
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) 40-504
Failure code [DAJQKR] CAN2 Discon ( HST Con) 40-506
Failure code [DAJRKR] CAN1 Discon ( HST Con) 40-507
Failure code [DAJRMA] Inconsistency of Option Selection (HST) 40-508
Failure code [DAZ9KQ] A/C Model Selection Abnormality 40-509
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 40-510
Failure code [DB2QKR] CAN2 Discon (Engine Con) 40-511
Failure code [DB2RKR] CAN1 Discon (Engine Con) 40-516
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW 40-520
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 40-522
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction 40-524
Failure code [DDB6L4] Parking Brake Signal Malfunction 40-526
Failure code [DDD7KA] Failure of Variable Speed Control 40-529
Failure code [DDD7KY] Hot Short of Variable Speed Control 40-531
Failure code [DDK3KA] FNR SW Input Signal Disconnection 40-533
Failure code [DDK3KB] FNR SW Input Signal Short Circuit 40-535
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 40-537
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit 40-540
Failure code [DDNRLD] Ground Fault of Work Equip Lock Switch 40-542
Failure code [DF10KA] Disconnection of Speed Range Input 40-544
Failure code [DF10KB] Ground Fault of Speed Range Input 40-547
Failure code [DGH1KX] Out of Range of HST Oil Temp Sensor 40-550
Failure code [DGR2KB] Ground Fault of Brake Oil Temp Sensor 40-552
Failure code [DGR2KZ] Failure of Brake Oil Temp Sensor 40-554
Failure code [DHHBKA] Failure of HST Press Sens Circuit (MA) 40-556
Failure code [DHHBKY] Hot Short of HST Press Sens Circuit (MA) 40-558
Failure code [DHHCKA] Failure of HST Press Sens Circuit (MB) 40-560
Failure code [DHHCKY] Hot Short of HST Press Sens Circuit (MB) 40-562
Failure code [DHPCKA] Failure of Boom Press Sensor (Bottom) 40-564
Failure code [DHPCKY] Hot Short of Boom Press Sensor (Bottom) 40-566
Failure code [DHPEKA] Failure of Steering & Loader Pump Press 40-568
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press 40-570
Failure code [DHS8KA] Failure of Boom Raise PPC Sens Circuit 40-572
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens Circuit 40-574
Failure code [DHS9KA] Failure of Boom Lower PPC Sens Circuit 40-576
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens Circuit 40-578
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens Circuit 40-580
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens Circuit 40-582
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens Circuit 40-584
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens Circuit 40-586
Failure code [DHT8ZG] Steering Oil Pressure Low 40-588
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit 40-589
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 40-591
Failure code [DK55KA] Failure of FNR Lever Potentio 40-593
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit 40-596
Failure code [DK55L5] Failure of FNR Lever Potentio 40-598
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) 40-599
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) 40-602
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree 40-605
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) 40-608
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) 40-611
Failure code [DK70KA] Failure of inching sensor Circuit 40-614
Failure code [DK70KY] Hot Short of inching sensor Circuit 40-617
Failure code [DKA0KA] Failure of Boom Angle Sensor 40-619
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit 40-621
Failure code [DKA0L0] Boom Angle Sensor Dislocation 40-623
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 40-625
WA270-7 00-9
00 Index and foreword
Index
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 40-627
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) 40-628
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) 40-630
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) 40-632
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) 40-635
Failure code [DPQ1KR] LIN Discon (Switch Panel) 40-637
Failure code [DPQ2KR] LIN Discon (LED Unit) 40-640
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 40-643
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 40-646
Failure code [DT22KB] Ground Fault of Work Equip Lock Indic 40-648
Failure code [DV00KB] Ground Fault of Buzzer Output 40-650
Failure code [DW26KA] Disconnection of Motor 2 Solenoid 40-652
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid 40-654
Failure code [DW26KY] Hot Short of Motor 2 Solenoid 40-656
Failure code [DW4BKA] Disconnection of Parking Brake Valve 40-658
Failure code [DW4BKB] Ground Fault of Parking Brake Valve 40-660
Failure code [DW4BKY] Hot Short of Parking Brake Valve 40-662
Failure code [DW4RKA] Disconnection of Bucket EPC Sol (Tilt) 40-663
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) 40-665
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) 40-667
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid 40-668
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid 40-670
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid 40-672
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) 40-673
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) 40-675
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) 40-677
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) 40-679
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) 40-681
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) 40-683
Failure code [DX19KA] Disconnection of Motor 1 Solenoid 40-684
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid 40-686
Failure code [DX19KY] Hot Short of Motor 1 Solenoid 40-688
Failure code [DX20KA] Disconnection of Clutch Control Solenoid 40-690
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid 40-692
Failure code [DX20KY] Hot Short of Clutch Control Solenoid 40-694
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol 40-696
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol 40-698
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol 40-700
Failure code [DXH7KA] Disconnection of Reverse Solenoid 40-702
Failure code [DXH7KB] Ground Fault of Reverse Solenoid 40-704
Failure code [DXH7KY] Hot Short of Reverse Solenoid 40-706
Failure code [DXH8KA] Disconnection of Forward Solenoid 40-708
Failure code [DXH8KB] Ground Fault of Forward Solenoid 40-710
Failure code [DXH8KY] Hot Short of Forward Solenoid 40-712
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) 40-714
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 40-716
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) 40-718
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) 40-719
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 40-721
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) 40-723
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal 40-724
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal 40-727
Failure code [J141N1] Steering Pump Over Run 40-729
Failure code [LA00L3] Failure of Fan Reverse 40-730
Failure code [M100N1] HST Pump Over Run 40-731
Failure code [M400N1] HST Motor 1 Over Run 40-732
Troubleshooting of electrical system (E-mode) 40-733
E-1 Engine does not start 40-733
E-2 Manual preheating system does not work 40-740
00-10 WA270-7
00 Index and foreword
Index
E-3 Automatic preheating system does not work 40-743
E-4 While preheating is working, preheating monitor does not light up 40-745
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing 40-747
E-6 LCD unit on machine monitor displays nothing 40-750
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) 40-752
E-8 LCD on machine monitor does not display properly 40-754
E-9 Meter unit display on machine monitor is abnormal 40-756
E-10 Night lighting lamp of meter unit on machine monitor is abnormal 40-759
E-11 Caution LED on machine monitor is abnormal 40-762
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate
properly 40-764
E-13 Two switches operation of switch panel on machine monitor does not function 40-766
E-14 Switch panel buzzer of machine monitor is abnormal 40-769
E-15 Rearview monitor does not light up or backlight flickers 40-771
E-16 Rearview monitor images are not displayed clearly 40-774
E-17 Rearview monitor brightness cannot be adjusted 40-777
E-18 Night lighting lamp of rearview monitor is abnormal 40-780
E-19 Some items of gauges and caution lamps on machine monitor are not displayed
properly 40-782
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position 40-783
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
light 40-787
E-22 The HSToil filter clogging caution lamp does not light up 40-789
E-23 Radiator coolant level caution lamp does not light 40-791
E-24 Indication of HSToil temperature gauge does not increase, or HSToil temperature
caution lamp does not light 40-793
E-25 When brake pedal (inching pedal) is depressed, inching function does not work (travel
speed or traction force does not lower), or while not depressed, inching function
operates 40-794
E-26 Fuel level gauge does not indicate correct level 40-796
E-27 Seat belt caution lamp indication is abnormal 40-798
E-28 Horn does not sound 40-799
E-29 Horn does not stop sounding 40-802
E-30 Alarm buzzer does not sound 40-804
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding 40-806
E-32 When emergency HST pump drive switch is operated, emergency HST pump does not
work or when emergency HST pump drive switch is not operated, emergency HST
pump works 40-807
E-33 Setting does not change while operating traction control switch 40-809
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake
is released and FR drive is operated 40-811
E-35 Remote positioner does not work or cannot be released 40-814
E-36 Bucket positioner does not work or cannot be released 40-816
E-37 Direction selector (FNR) switch mode is not selected or not released 40-819
E-38 PZ auto tilt-in does not work 40-821
E-39 Tracktion level does not display MAX when max traction switch is turned ON 40-824
E-40 ECSS function cannot be selected or cannot be released 40-826
E-41 None of headlamp, clearance lamp, and tail lamp lights 40-828
E-42 Clearance lamp, tail lamp and license-plate lamp do not light up or go out 40-830
E-43 Both High and Low beams of headlamp do not light up or go out 40-834
E-44 Low beam of headlamp does not light up or go out 40-838
E-45 High beam of headlamp does not light up or go out 40-840
E-46 Front working lamp does not light up or go out 40-842
E-47 Rear working lamp does not light up or go out 40-846
E-48 All of turn signal lamps and hazard lamps do not flash or go out 40-850
E-49 Turn signal lamps do not flash or go out 40-853
E-50 Hazard lamp does not flash or go out 40-856
WA270-7 00-11
00 Index and foreword
Index
E-51 Brake lamp does not light or stays lighted 40-859
E-52 Backup lamp does not light up or does not go out 40-862
E-53 Backup buzzer does not sound or continues to sound 40-865
E-54 Front wiper does not operate 40-867
E-55 Rear wiper does not operate 40-870
E-56 Window washer does not operate 40-872
E-57 KOMTRAX system does not operate normally 40-875
Troubleshooting of hydraulic and mechanical system (H-mode) 40-877
Information described in troubleshooting table (H-mode) 40-877
System chart of hydraulic and mechanical systems 40-878
Failure mode and cause table 40-880
H-1 Machine does not travel forward or backward 40-886
H-2 Machine does not travel forward (Machine travels backward normally) 40-889
H-3 Machine does not travel backward (Machine travels forward normally) 40-890
H-4 Machine does not travel forward or backward fast 40-891
H-5 Machine does not travel forward fast (Machine travel backward fast) 40-895
H-6 Machine does not travel backward fast (Machine travel forward fast) 40-896
H-7 Machine lacks power neither when traveling forward nor backward 40-897
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling
backward) 40-900
H-9 Machine lacks power when traveling backward (Machine have sufficient power when
traveling forward) 40-901
H-10 Engine stalls during travel or engine speed drops significantly 40-902
H-11 Steering wheel is too heavy to turn 40-903
H-12 Steering wheel is heavy to turn 40-905
H-13 Machine sways or large shocks are made while machine turns 40-906
H-14 Machine unintentionally turns when machine travels 40-907
H-15 Wheel brakes do not work or are weak 40-908
H-16 Wheel brakes are not released or drag 40-909
H-17 Parking brake does not work or it is weak 40-910
H-18 Parking brake is not released or drags 40-911
H-19 Boom does not rise 40-912
H-20 Boom moves slow or boom lacks lifting force 40-914
H-21 Rising boom slows down at certain height 40-916
H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground) 40-917
H-23 Hydraulic drift of boom is large 40-918
H-24 Boom moves up and down during operation 40-919
H-25 Bucket does not tilt back 40-920
H-26 Bucket moves slow or lacks tilt-back force 40-922
H-27 Bucket decelerates during tilt-back operation 40-924
H-28 Bucket cylinder does not hold bucket on ground 40-925
H-29 Hydraulic drift of bucket is large 40-926
H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) 40-927
H-31 Boom and bucket control levers do not move smoothly and are heavy to move 40-928
H-32 Operating work equipment causes engine speed to lower significantly or engine to
stall 40-929
H-33 Large shocks are made when work equipment starts to move and stops 40-930
H-34 When certain work equipment is relieved hydraulically, other work equipment
moves 40-931
H-35 E C S S (travel damper) does not work and machine pitches and bounces 40-932
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) 40-933
H-37 Unusual noise is heard from around fan 40-935
Troubleshooting of engine (S-mode) 40-936
Information described in troubleshooting table (S mode) 40-936
S-1 Engine does not crank when starting switch is turned to START position 40-937
S-2 Engine cranks but no exhaust smoke comes out 40-938
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start) 40-939
S-4 Engine startability is poor 40-940
00-12 WA270-7
00 Index and foreword
Index
S-5 Engine does not pick up smoothly 40-942
S-6 Engine stops during operation 40-944
S-7 Engine runs rough or is unstable 40-946
S-8 Engine lacks power 40-947
S-9 KDPF gets clogged in a short time 40-949
S-10 Engine oil consumption is excessive 40-951
S-11 Engine oil becomes contaminated early 40-952
S-12 Fuel consumption is excessive 40-953
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 40-954
S-14 Oil pressure drops 40-955
S-15 Fuel mixes into engine oil 40-956
S-16 Water mixes into engine oil (milky) 40-957
S-17 Coolant temperature rises too high (overheating) 40-958
S-18 Unusual noise is heard 40-959
S-19 Vibration is excessive 40-960
S-20 Air cannot be bled from fuel circuit 40-962
S-21 Active regeneration is executed frequently 40-963
S-22 Active regeneration takes time 40-964
S-23 White smoke is exhausted during active regeneration 40-965
50 Disassembly and assembly 50-1
Table of contents 50-2
Related information on disassembly and assembly 50-4
How to read this manual 50-4
Coating materials list 50-6
Special tools list 50-10
Sketches of special tools 50-17
Engine and cooling system 50-33
Removal and installation of supply pump assembly 50-33
Removal and installation of injector assembly 50-37
Removal and installation of cylinder head assembly 50-46
Removal and installation of engine hood assembly 50-53
Removal and installation of grille assembly 50-56
Removal and installation of radiator core assembly 50-58
Removal and installation of aftercooler 50-61
Removal and installation of hydraulic oil cooler 50-63
Removal and installation of engine assembly 50-64
Removal and installation of engine front oil seal 50-70
Removal and installation of engine rear oil seal 50-73
Removal and installation of cooling fan and fan motor assembly 50-76
Removal and installation of KDPF assembly 50-78
Disassembly and assembly of KDPF assembly 50-82
Removal and installation of KCCV assembly 50-91
Removal and installation of air cleaner assembly 50-92
Removal and installation of KVGTassembly 50-94
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 50-98
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 50-100
Removal and installation of alternator belt 50-103
Removal and installation of fuel tank assembly 50-105
Power train 50-108
Removal and installation of transfer assembly 50-108
Disassembly and assembly of transfer assembly 50-113
Disassembly and assembly of parking brake assembly 50-145
Disassembly and assembly of differential assembly 50-153
Removal and installation of front axle assembly 50-177
Removal and installation of rear axle assembly 50-179
Disassembly and assembly of axle housing assembly 50-182
Undercarriage and frame 50-191
Removal and installation of center hinge pin 50-191
Removal and installation of counterweight assembly 50-200
WA270-7 00-13
00 Index and foreword
Index
Hydraulic system 50-202
Removal and installation of hydraulic tank assembly 50-202
Removal and installation of control valve assembly 50-205
Disassembly and assembly of control valve assembly 50-209
Removal and installation of hydraulic pump assembly 50-212
Removal and installation of HST motor1 assembly 50-216
Removal and installation of HST motor2 assembly 50-218
Disassembly and assembly of hydraulic cylinder assembly 50-220
Work equipment 50-227
Removal and installation of work equipment assembly 50-227
Cab and its attachments 50-233
Removal and installation of operator’s cab and floor frame assembly 50-233
Removal and installation of operator’s cab glass (adhered glass) 50-238
Removal and installation of operator’s seat assembly 50-246
Removal and installation of seat belt 50-248
Electrical system 50-249
Removal and installation of machine monitor assembly 50-249
Removal and installation of engine controller assembly 50-251
Removal and installation of HSTcontroller assembly 50-253
Removal and installation of air conditioner controller assembly 50-255
Removal and installation of monitor controller assembly 50-256
Removal and installation of mass air flow and temperature sensor 50-258
Removal and installation of KOMTRAX terminal assembly 50-259
Air conditioner unit 50-260
Removal and installation of air conditioner compressor 50-260
Removal and installation of air conditioner condenser 50-262
Removal and installation of air conditioner unit assembly 50-264
60 Maintenance standard 60-1
Table of contents 60-2
Engine and cooling system 60-3
Engine related parts 60-3
Cooling fan motor 60-4
Power train 60-6
Damper 60-6
Transfer 60-7
Drive shaft 60-14
Axle 60-15
Differential 60-17
Limited slip differential 60-21
Final drive 60-23
Steering system 60-27
Steering column 60-27
Priority valve 60-28
Emergency steering valve 60-29
Steering cylinder 60-30
Brake system 60-32
Brake accumulator charge valve 60-32
Slack adjuster 60-33
Brake 60-34
Parking brake 60-36
Parking brake solenoid valve 60-37
Undercarriage and frame 60-38
Axle mount 60-38
Center hinge pin 60-40
Hydraulic system 60-44
Hydraulic tank 60-44
Double type gear pump 60-45
Steering and work equipment pump 60-46
Control valve 60-50
00-14 WA270-7
00 Index and foreword
Index
Self-pressure reducing valve 60-63
Work equipment PPC valve 60-65
Work equipment lock solenoid valve 60-67
Work equipment 60-68
Work equipment linkage 60-68
Bucket 60-72
Work equipment cylinder 60-74
Cab and its attachments 60-75
Cab mount 60-75
Electrical system 60-76
Bucket positioner 60-76
Fork positioner 60-77
Remote boom positioner 60-78
80 Appendix 80-1
Table of contents 80-2
Air conditioner components 80-3
Precautions for refrigerant 80-3
Air conditioner component 80-4
Configuration and function of refrigeration cycle 80-6
Outline of refrigeration cycle 80-7
Air conditioner unit 80-9
Dual pressure switch 80-14
Air conditioner controller 80-15
Compressor 80-16
Condenser 80-17
Receiver drier 80-18
Sunlight sensor 80-20
Outer temperature sensor (outside air temperature sensor) 80-21
Procedure for testing and troubleshooting 80-22
Circuit diagram and arrangement of connector pins 80-24
System diagram 80-27
Parts and connectors layout 80-30
Testing with self-diagnosis function 80-35
How to open the electrical system abnormality record screen in service mode of the machine
monitor 80-36
Testing temperature control system 80-38
Testing vent (mode) changeover 80-40
Testing FRESH/RECIRC air changeover 80-42
Testing evaporator temperature sensor 80-44
Testing relays 80-46
Troubleshooting chart 1 80-48
Troubleshooting chart 2 80-49
Information in troubleshooting table 80-51
Failure code list related to air conditioner 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit 80-55
Failure code [879BKA] A/C Outer Sensor Open Circuit 80-57
Failure code [879BKB] A/C Outer Sensor Short Circuit 80-59
Failure code [879CKA] Ventilating Sensor Open Circuit 80-61
Failure code [879CKB] Ventilating Sensor Short Circuit 80-63
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 80-65
Failure code [879EMC] Ventilation Damper Abnormality 80-67
Failure code [879FMC] Air Mix Damper Abnormality 80-70
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does
not operate) 80-73
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 80-76
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) 80-79
A-4 Troubleshooting for FRESH/RECIRC air changeover 80-82
WA270-7 00-15
00 Index and foreword
Index
Troubleshooting with gauge pressure 80-84
Connection of service tool 80-87
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit 80-89
Handling of compressor oil 80-91
90 Diagrams and drawings 90-1
Table of contents 90-2
Hydraulic circuit diagram 90-3
Symbols in hydraulic circuit diagram 90-3
Hydraulic circuit diagram 90-7
Electric circuit diagram 90-9
Symbols in electric circuit diagram 90-9
Electrical circuit diagram of machine body 90-13
Electrical circuit diagram of floor 90-21
Index 1

IMAGES PREVIEW OF THE MANUAL: