Komatsu WA320-7 Wheel Loader Shop Manual SEN06202-06 – PDF DOWNLOAD

Komatsu WA320-7 Wheel Loader Shop Manual SEN06202-06 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA320-7 Wheel Loader Shop Manual SEN06202-06 – PDF DOWNLOAD

Language : English
Pages : 2078
Downloadable : Yes
File Type : PDF
Size: 60 MB

DESCRIPTION:

Komatsu WA320-7 Wheel Loader Shop Manual SEN06202-06 – 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 WA320-7 Wheel Loader Shop Manual SEN06202-06 – PDF DOWNLOAD

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 19
Important safety notice 19
How to read the shop manual 26
Explanation of terms for maintenance standard 28
Handling equipment of fuel system devices 30
Handling of intake system parts 31
Handling of hydraulic equipment 32
Method of disconnecting and connecting of push-pull type coupler 34
Handling of electrical equipment 37
How to read electric wire code 45
Precautions when performing operation 48
Practical use of KOMTRAX 53
Standard tightening torque table 54
List of abbreviation 60
Conversion table 65
01 Specification 71
Table of contents 72
Specifications 73
Specification drawing 73
Specifications 77
Weight table 87
Table of fuel, coolant, and lubricants 91
10 Structure and function 93
Table of contents 94
Engine and cooling system 96
Engine related parts 96
KVGT 98
EGR system piping drawing 105
EGR system circuit diagram 107
EGR valve 109
EGR cooler 111
KCCV layout drawing 112
KCCV ventilator 114
KDPF 116
Cooling system 120
Cooling fan motor 122
Power train 132
Power train system 132
Layout of power train parts 134
Damper 135
HST pump 136
HST motor1 149
HST motor2 151
Transfer 156
Clutch solenoid valve 163
Drive shaft 165
Axle 166
Differential 168
Torque proportional differential 172
Limited slip differential 174
Final drive 179
Steering system 181
Layout of steering devices 181
Steering column 182
Priority valve 183
Cushion valve 187
Emergency steering valve 188
Orbitrol valve 191
Brake system 197
Layout of brake parts 197
Brake accumulator charge valve 199
Brake valve 204
Brake accumulator 208
Slack adjuster 209
Brake 211
Parking brake control 214
Parking brake 215
Parking brake solenoid valve 216
Undercarriage and frame 218
Axle mount 218
Center hinge pin 220
Tire 221
Hydraulic system 223
Hydraulic component layout 223
Work equipment control 225
Hydraulic tank 226
Double type gear pump 229
Steering and work equipment pump 230
Control valve 242
CLSS 252
Hydraulic circuit diagram and names of valves 256
Self-pressure reducing valve 269
Work equipment PPC valve 274
Work equipment lock solenoid valve 282
PPC circuit accumulator 283
ECSS accumulator 284
Work equipment 285
Work equipment linkage 285
Bucket 286
Cab and its attachments 287
ROPS cab 287
Cab mount 289
Electrical system 290
Engine control system 290
Preheating system 293
Engine output limit function 295
Automatic warm-up function 296
Parking brake control system 297
System operating lamp function 301
Battery disconnect switch function 302
HST controller system 304
Machine monitor system 344
Rearview monitor system 365
KOMTRAX system 368
System component parts 371
Sensor 394
20 Standard value tables 415
Table of contents 416
Standard service value table 417
Standard value table for engine 417
Standard value table for machine 419
Standard value table for electrical system 431
30 Testing and adjusting 441
Table of contents 442
Related information on testing and adjusting 444
Tools for testing and adjusting 444
Sketch of tools for testing and adjusting 450
Engine and cooling system 451
Testing engine speed 451
Testing boost pressure 452
Testing exhaust gas temperature 454
Testing exhaust gas color 455
Testing and adjusting valve clearance 457
Testing compression pressure 460
Testing blowby pressure 464
Testing engine oil pressure 465
Testing EGR valve and KVGT oil pressures 466
Testing fuel pressure 467
Testing fuel discharge, return and leakage 472
Bleeding air from fuel system 477
Testing fuel circuit for leakage 479
Handling cylinder cutout mode operation 480
Handling no-injection cranking operation 481
Testing of KDPF and muffler stack for looseness and damage 482
Testing of installed condition of cylinder heads and manifolds 483
Testing engine piping for damage and looseness 484
Testing and adjusting air conditioner compressor belt tension 485
Check alternator belt, replace 486
Check auto-tensioner, replace 488
Writing compensation amount for soot accumulation caused by ash on engine controller 490
Power train 492
Testing oil leakage from axle final drive 492
Testing drive shaft for looseness, backlash, and damage 493
Testing accelerator pedal 494
Testing and adjusting HST oil pressure 495
Testing transfer clutch control pressure 498
Steering system 499
Testing directional lever 499
Testing steering wheel 500
Testing work equipment control lever 502
Testing and adjusting steering circuit oil pressure 504
Bleeding air from steering cylinder circuit 506
Brake system 507
Testing brake pedal 507
Testing braking performance 508
Testing and adjusting of accumulator charge pressure 509
Testing wheel brake oil pressure 511
Testing lowering of wheel brake pressure 512
Testing wear of wheel brake disc 514
Bleeding air from wheel brake circuit 515
Releasing remaining pressure in brake accumulator circuit 516
Testing parking brake performance 517
Testing wear of parking brake disc 518
Testing parking brake release pressure 519
Method of releasing parking brake manually 520
Hydraulic system 521
Testing cooling fan speed 521
Testing cooling fan pump circuit oil pressure 522
Bleeding air from hydraulic fan circuit 524
Testing and adjusting work equipment PPC oil pressure 525
Testing and adjusting work equipment oil pressure 527
Bleeding air from work equipment circuit 531
Releasing remaining pressure from work equipment circuit 532
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 534
Work equipment 538
Testing and adjusting bucket positioner and bucket proximity switch 538
Testing and adjusting boom position detection lever 540
Electrical system 541
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 541
Special functions of machine monitor 542
Adjusting rearview camera angle 621
Handling voltage circuit of engine controller 622
Handling battery disconnect switch 623
Testing diodes 624
Pm clinic 625
Pm Clinic service 625
Check sheet 626
40 Troubleshooting 633
Table of contents 634
Related information on troubleshooting 643
Troubleshooting points 643
Sequence of events in troubleshooting 645
Checks before troubleshooting 647
Inspection procedure before troubleshooting 649
Preparation for troubleshooting of electrical system 666
Classification and procedures for troubleshooting 672
Symptom and troubleshooting numbers 675
Information in troubleshooting table 678
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit 680
Connector list and layout 683
Connector contact identification 697
T-branch box and T-branch adapter table 736
Fuse location table 741
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 744
Precautions when performing troubleshooting of machine monitor 747
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit 749
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 754
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 755
Failure codes table 756
Troubleshooting by failure code (Display of code) 768
Failure code [2F00MA] Failure of Parking Brake Circuit 768
Failure code [2F00MB] Malfunction of Parking Brake 771
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 773
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 775
Failure code [6091NX] HST Oil Filter Clogging 777
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol 779
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol 781
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol 783
Failure code [879AKA] A/C Inner Sensor Open Circuit 785
Failure code [879AKB] A/C Inner Sensor Short Circuit 786
Failure code [879BKA] A/C Outer Sensor Open Circuit 787
Failure code [879BKB] A/C Outer Sensor Short Circuit 788
Failure code [879CKA] Ventilating Sensor Open Circuit 789
Failure code [879CKB] Ventilating Sensor Short Circuit 790
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 791
Failure code [879EMC] Ventilation Damper Abnormality 792
Failure code [879FMC] Air Mix Damper Abnormality 793
Failure code [989L00] Engine Controller Lock Caution 1 794
Failure code [989M00] Engine Controller Lock Caution 2 795
Failure code [989N00] Engine Controller Lock Caution 3 796
Failure code [A1U0N3] HC Desorb Request 1 797
Failure code [A1U0N4] HC Desorb Request 2 799
Failure code [AA10NX] Air Cleaner Clogging 801
Failure code [AB00KE] Charge Voltage Low 803
Failure code [AB00KY] Hot Short of Alternator R Terminal 804
Failure code [B@BAZG] Eng Oil Press Low 805
Failure code [B@BAZK] Engine Oil Level Low 806
Failure code [B@BCNS] Eng Water Overheat 808
Failure code [B@BCZK] Eng Water Level Low 809
Failure code [B@CRNS] HST Oil Temp Overheat 811
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 812
Failure code [CA122] Chg Air Press Sensor High Error 813
Failure code [CA123] Chg Air Press Sensor Low Error 815
Failure code [CA131] Throttle Sensor High Error 817
Failure code [CA132] Throttle Sensor Low Error 819
Failure code [CA144] Coolant Temp Sens High Error 821
Failure code [CA145] Coolant Temp Sens Low Error 823
Failure code [CA153] Chg Air Temp Sensor High Error 825
Failure code [CA154] Chg Air Temp Sensor Low Error 827
Failure code [CA187] Sensor 2 Supply Volt Low Error 829
Failure code [CA221] Ambient Press Sensor High Error 831
Failure code [CA222] Ambient Press Sensor Low Error 833
Failure code [CA227] Sensor 2 Supply Volt High Error 835
Failure code [CA234] Eng Overspeed 836
Failure code [CA238] Ne Speed Sensor Supply Volt Error 837
Failure code [CA239] Ne Speed Sens Supply Volt High Error 838
Failure code [CA271] IMV/PCV1 Short Error 839
Failure code [CA272] IMV/PCV1 Open Error 841
Failure code [CA295] Ambient Press Sens In Range Error 843
Failure code [CA322] Inj #1(L#1) Open/Short Error 844
Failure code [CA323] Inj #5(L#5) Open/Short Error 846
Failure code [CA324] Inj #3(L#3) Open/Short Error 848
Failure code [CA325] Inj #6(L#6) Open/Short Error 850
Failure code [CA331] Inj #2(L#2) Open/Short Error 852
Failure code [CA332] Inj #4(L#4) Open/Short Error 854
Failure code [CA343] ECM Critical Internal Failure 856
Failure code [CA351] Injectors Drive Circuit Error 857
Failure code [CA352] Sensor 1 Supply Volt Low Error 858
Failure code [CA356] Mass Air Flow Sensor High Error 860
Failure code [CA357] Mass Air Flow Sensor Low Error 862
Failure code [CA386] Sensor 1 Supply Volt High Error 864
Failure code [CA428] Water in Fuel Sensor High Error 865
Failure code [CA429] Water in Fuel Sensor Low Error 867
Failure code [CA431] Idle Validation Sw Error 869
Failure code [CA432] Idle Validation Process Error 872
Failure code [CA435] Eng Oil Press Sw Error 875
Failure code [CA441] Battery Voltage Low Error 876
Failure code [CA442] Battery Voltage High Error 878
Failure code [CA449] Rail Press Very High Error 879
Failure code [CA451] Rail Press Sensor High Error 880
Failure code [CA452] Rail Press Sensor Low Error 882
Failure code [CA488] Chg Air Temp High Torque Derate 884
Failure code [CA515] Rail Press Sens Sup Volt High Error 885
Failure code [CA516] Rail Press Sens Sup Volt Low Error 887
Failure code [CA553] Rail Press High Error 889
Failure code [CA555] Crankcase Press High Error 1 890
Failure code [CA556] Crankcase Press High Error 2 891
Failure code [CA559] Rail Press Low Error 892
Failure code [CA595] Turbo Speed High Error 2 894
Failure code [CA687] Turbo Speed Low Error 895
Failure code [CA689] Eng Ne Speed Sensor Error 897
Failure code [CA691] Intake Air Temp Sens High Error 899
Failure code [CA692] Intake Air Temp Sens Low Error 901
Failure code [CA697] ECM Internal Temp Sensor High Error 903
Failure code [CA698] ECM Int Temp Sensor Low Error 904
Failure code [CA731] Eng Bkup Speed Sens Phase Error 905
Failure code [CA778] Eng Bkup Speed Sensor Error 907
Failure code [CA1117] Persistent Data Lost Error 912
Failure code [CA1664] KDOC Malfunction 913
Failure code [CA1691] Regeneration Ineffective 916
Failure code [CA1695] Sensor 5 Supply Volt High Error 919
Failure code [CA1696] Sensor 5 Supply Volt Low Error 920
Failure code [CA1843] Crankcase Press Sens High Error 922
Failure code [CA1844] Crankcase Press Sens Low Error 924
Failure code [CA1879] KDPF Delta P Sensor High Error 926
Failure code [CA1881] KDPF Delta P Sensor Low Error 928
Failure code [CA1883] KDPF Delta P Sens In Range Error 930
Failure code [CA1921] KDPF Soot Load High Error 1 934
Failure code [CA1922] KDPF Soot Load High Error 2 937
Failure code [CA1942] Crankcase Press Sens In Range Error 942
Failure code [CA1993] KDPF Delta Pressure Low Error 943
Failure code [CA2185] Throt Sensor Sup Volt High Error 946
Failure code [CA2186] Throt Sensor Sup Volt Low Error 948
Failure code [CA2249] Rail Press Very Low Error 950
Failure code [CA2271] EGR Valve Pos Sens High Error 951
Failure code [CA2272] EGR Valve Pos Sens Low Error 953
Failure code [CA2288] Turbo Speed High Error 1 956
Failure code [CA2311] IMV Solenoid Error 957
Failure code [CA2349] EGR Valve Solenoid Open Error 958
Failure code [CA2353] EGR Valve Solenoid Short Error 960
Failure code [CA2357] EGR Valve Servo Error 962
Failure code [CA2373] Exhaust Manifold Press Sens High error 963
Failure code [CA2374] Exhaust Manifold Press Sens Low error 965
Failure code [CA2375] EGR Orifice Temp Sens High Error 967
Failure code [CA2376] EGR Orifice Temp Sens Low Error 969
Failure code [CA2381] KVGT Pos Sens High Error 971
Failure code [CA2382] KVGT Pos Sens Low Error 973
Failure code [CA2383] KVGT Solenoid Open Error 976
Failure code [CA2386] KVGT Solenoid Short Error 978
Failure code [CA2387] KVGT Servo Error 980
Failure code [CA2554] Exh Manifold Press Sens In Range Error 981
Failure code [CA2555] Grid Htr Relay Volt Low Error 982
Failure code [CA2556] Grid Htr Relay Volt High Error 984
Failure code [CA2637] KDOC Face Plugging 986
Failure code [CA2639] Manual Stationary Regeneration Request 988
Failure code [CA2961] EGR Orifice Temp High Error 1 991
Failure code [CA2973] Chg Air Press Sensor In Range Error 992
Failure code [CA3133] KDPF Outlet Press Sens High Error 993
Failure code [CA3134] KDPF Outlet Press Sens Low Error 995
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 997
Failure code [CA3251] KDOC Inlet Temp High Error 1001
Failure code [CA3253] KDOC Temp Error – Non Regeneration 1004
Failure code [CA3254] KDOC Outlet Temp High Error 1 1008
Failure code [CA3255] KDPF Temp Error – Non Regeneration 1011
Failure code [CA3256] KDPF Outlet Temp High Error 1 1015
Failure code [CA3311] KDOC Outlet Temp High Error 2 1018
Failure code [CA3312] KDPF Outlet Temp High Error 2 1022
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 1026
Failure code [CA3314] KDOC Inlet Temp Sens High Error 1029
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 1032
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 1036
Failure code [CA3317] KDOC Outlet Temp Sens High Error 1039
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 1042
Failure code [CA3319] KDPF Outlet Temp Sens High Error 1046
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 1049
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 1052
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 1056
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 1058
Failure code [CA3741] Rail Press Valve Trip Error 1060
Failure code [D110L4] Disconnection of Battery Relay Signal 1061
Failure code [D160KA] Disconnection of Backup Lamp Relay Output 1063
Failure code [D160KY] Hot Short of Backup Lamp Relay Output 1065
Failure code [D191KA] Disconnection of Neutral Output Relay 1067
Failure code [D191KB] Ground Fault of Neutral Output Relay 1069
Failure code [D191KY] Hot Short of Neutral Output Relay 1071
Failure code [D192KA] Disconnection of ECSS Solenoid 1073
Failure code [D192KB] Ground Fault of ECSS Solenoid 1075
Failure code [D192KY] Hot Short of ECSS Solenoid 1076
Failure code [D19JKZ] Personal Code Relay Abnormality 1077
Failure code [D1B0KA] Disconnection of HST Safety Relay 1079
Failure code [D1B0KB] Ground Fault of HST Safety Relay 1081
Failure code [D1B0KY] Hot Short of HST Safety Relay 1083
Failure code [D1B0MC] Malfunction of HST Safety Relay 1085
Failure code [D1E6KA] Disconnection of Parking Brake Relay 1086
Failure code [D1E6KB] Ground Fault of Parking Brake Relay 1088
Failure code [D1E6KY] Hot Short of Parking Brake Relay 1090
Failure code [D5ZHKA] Failure of Key SW C Signal 1092
Failure code [D5ZHKB] Key SW C Signal Short Circuit 1094
Failure code [D5ZHL6] Disconnection of Key SW C 1096
Failure code [D811MC] KOMTRAX Error 1097
Failure code [D862KA] GPS Antenna Open Circuit 1098
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 1099
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 1101
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 1103
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 1104
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 1106
Failure code [DAF0MB] Monitor ROM Abnormality 1107
Failure code [DAF0MC] Monitor Error 1108
Failure code [DAF3KK] Controller Power Source Low (MON) 1109
Failure code [DAF8KB] Camera Power Supply Short Circuit 1111
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 1112
Failure code [DAFGMC] GPS Module Error 1113
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) 1114
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 1116
Failure code [DAFQKR] CAN2 Discon (Monitor) 1118
Failure code [DAJ0KK] Controller Power Source Low (HST) 1119
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) 1122
Failure code [DAJ0MC] HST Con Error 1123
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) 1124
Failure code [DAJ2KK] Solenoid Power Source Low (HST) 1126
Failure code [DAJ4KB] Ground Fault of Sol Self-Holding Relay 1129
Failure code [DAJ4KZ] Failure of Sol Self-Holding Relay 1131
Failure code [DAJ5KX] Failure of 5V Power Source 0 1133
Failure code [DAJ6KX] Failure of 5V Power Source 1 1135
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) 1137
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) 1138
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) 1140
Failure code [DAJQKR] CAN2 Discon ( HST Con) 1142
Failure code [DAJRKR] CAN1 Discon ( HST Con) 1143
Failure code [DAJRMA] Inconsistency of Option Selection (HST) 1144
Failure code [DAZ9KQ] A/C Model Selection Abnormality 1145
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1146
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1147
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1152
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW 1156
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 1158
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction 1160
Failure code [DDB6L4] Parking Brake Signal Malfunction 1162
Failure code [DDD7KA] Failure of Variable Speed Control 1165
Failure code [DDD7KY] Hot Short of Variable Speed Control 1167
Failure code [DDK3KA] FNR SW Input Signal Disconnection 1169
Failure code [DDK3KB] FNR SW Input Signal Short Circuit 1171
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 1173
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit 1176
Failure code [DDNRLD] Ground Fault of Work Equip Lock Switch 1178
Failure code [DF10KA] Disconnection of Speed Range Input 1180
Failure code [DF10KB] Ground Fault of Speed Range Input 1183
Failure code [DGH1KX] Out of Range of HST Oil Temp Sensor 1186
Failure code [DGR2KB] Ground Fault of Brake Oil Temp Sensor 1188
Failure code [DGR2KZ] Failure of Brake Oil Temp Sensor 1190
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit 1192
Failure code [DHHBKA] Failure of HST Press Sens Circuit (MA) 1194
Failure code [DHHBKY] Hot Short of HST Press Sens Circuit (MA) 1196
Failure code [DHHCKA] Failure of HST Press Sens Circuit (MB) 1198
Failure code [DHHCKY] Hot Short of HST Press Sens Circuit (MB) 1200
Failure code [DHPCKA] Failure of Boom Press Sensor (Bottom) 1202
Failure code [DHPCKY] Hot Short of Boom Press Sensor (Bottom) 1204
Failure code [DHPEKA] Failure of Steering & Loader Pump Press 1206
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press 1208
Failure code [DHS8KA] Failure of Boom Raise PPC Sens Circuit 1210
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens Circuit 1212
Failure code [DHS9KA] Failure of Boom Lower PPC Sens Circuit 1214
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens Circuit 1216
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens Circuit 1218
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens Circuit 1220
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens Circuit 1222
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens Circuit 1224
Failure code [DHT8ZG] Steering Oil Pressure Low 1226
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit 1227
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 1229
Failure code [DK55KA] Failure of FNR Lever Potentio 1231
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit 1234
Failure code [DK55L5] Failure of FNR Lever Potentio 1236
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) 1237
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) 1240
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree 1243
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) 1246
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) 1249
Failure code [DK70KA] Failure of inching sensor Circuit 1252
Failure code [DK70KY] Hot Short of inching sensor Circuit 1255
Failure code [DKA0KA] Failure of Boom Angle Sensor 1257
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit 1259
Failure code [DKA0L0] Boom Angle Sensor Dislocation 1261
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 1263
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 1265
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) 1266
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) 1268
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) 1270
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) 1273
Failure code [DPQ1KR] LIN Discon (Switch Panel) 1275
Failure code [DPQ2KR] LIN Discon (LED Unit) 1278
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 1281
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 1284
Failure code [DT22KB] Ground Fault of Work Equip Lock Indic 1286
Failure code [DV00KB] Ground Fault of Buzzer Output 1288
Failure code [DW26KA] Disconnection of Motor 2 Solenoid 1290
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid 1292
Failure code [DW26KY] Hot Short of Motor 2 Solenoid 1294
Failure code [DW4BKA] Disconnection of Parking Brake Valve 1296
Failure code [DW4BKB] Ground Fault of Parking Brake Valve 1298
Failure code [DW4BKY] Hot Short of Parking Brake Valve 1300
Failure code [DW4RKA] Disconnection of Bucket EPC Sol (Tilt) 1301
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) 1303
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) 1305
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid 1306
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid 1308
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid 1310
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) 1311
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) 1313
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) 1315
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) 1317
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) 1319
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) 1321
Failure code [DX19KA] Disconnection of Motor 1 Solenoid 1322
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid 1324
Failure code [DX19KY] Hot Short of Motor 1 Solenoid 1326
Failure code [DX20KA] Disconnection of Clutch Control Solenoid 1328
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid 1330
Failure code [DX20KY] Hot Short of Clutch Control Solenoid 1332
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol 1334
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol 1336
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol 1338
Failure code [DXH7KA] Disconnection of Reverse Solenoid 1340
Failure code [DXH7KB] Ground Fault of Reverse Solenoid 1342
Failure code [DXH7KY] Hot Short of Reverse Solenoid 1344
Failure code [DXH8KA] Disconnection of Forward Solenoid 1346
Failure code [DXH8KB] Ground Fault of Forward Solenoid 1348
Failure code [DXH8KY] Hot Short of Forward Solenoid 1350
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) 1352
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 1354
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) 1356
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) 1357
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 1359
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) 1361
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal 1362
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal 1365
Failure code [J141N1] Steering Pump Over Run 1367
Failure code [LA00L3] Failure of Fan Reverse 1368
Failure code [M100N1] HST Pump Over Run 1369
Failure code [M400N1] HST Motor 1 Over Run 1370
Troubleshooting of electrical system (E-mode) 1371
E-1 Engine does not start 1371
E-2 Manual preheating system does not work 1378
E-3 Automatic preheating system does not work 1381
E-4 While preheating is working, preheating monitor does not light up 1383
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing 1385
E-6 LCD unit on machine monitor displays nothing 1388
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) 1390
E-8 LCD on machine monitor does not display properly 1392
E-9 Meter unit display on machine monitor is abnormal 1394
E-10 Night lighting lamp of meter unit on machine monitor is abnormal 1397
E-11 Caution LED on machine monitor is abnormal 1400
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly 1402
E-13 Two switches operation of switch panel on machine monitor does not function 1404
E-14 Switch panel buzzer of machine monitor is abnormal 1407
E-15 Rearview monitor does not light up or backlight flickers 1409
E-16 Rearview monitor images are not displayed clearly 1412
E-17 Rearview monitor brightness cannot be adjusted 1415
E-18 Night lighting lamp of rearview monitor is abnormal 1418
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly 1420
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position 1421
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light 1425
E-22 Air cleaner clogging indicator lamp does not light 1427
E-23 Radiator coolant level caution lamp does not light 1429
E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light 1431
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 1432
E-26 Fuel level gauge does not indicate correct level 1434
E-27 Seat belt caution lamp indication is abnormal 1436
E-28 Horn does not sound 1437
E-29 Horn does not stop sounding 1440
E-30 Alarm buzzer does not sound 1442
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding 1444
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 1445
E-33 Setting does not change while operating traction control switch 1447
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 1449
E-35 Remote positioner does not work or cannot be released 1452
E-36 Bucket positioner does not work or cannot be released 1454
E-37 Direction selector (FNR) switch mode is not selected or not released 1457
E-38 PZ auto tilt-in does not work 1459
E-39 Tracktion level does not display MAX when max traction switch is turned ON 1462
E-40 ECSS function cannot be selected or cannot be released 1464
E-41 None of headlamp, clearance lamp, and tail lamp lights 1466
E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out 1468
E-43 Both High and Low beams of headlamp do not light up or go out 1472
E-44 Low beam of headlamp does not light up or go out 1476
E-45 High beam of headlamp does not light up or go out 1478
E-46 Front working lamp does not light up or go out 1480
E-47 Rear working lamp does not light up or go out 1484
E-48 All of turn signal lamps and hazard lamps do not flash or go out 1488
E-49 Turn signal lamps do not flash or go out 1491
E-50 Hazard lamp does not flash or go out 1494
E-51 Brake lamp does not light or stays lighted 1497
E-52 Backup lamp does not light up or does not go out 1500
E-53 Backup buzzer does not sound or continues to sound 1503
E-54 Front wiper does not operate 1505
E-55 Rear wiper does not operate 1508
E-56 Window washer does not operate 1510
E-57 KOMTRAX system does not operate normally 1513
Troubleshooting of hydraulic and mechanical system (H-mode) 1515
Information described in troubleshooting table (H-mode) 1515
System chart of hydraulic and mechanical systems 1516
Failure mode and cause table 1518
H-1 Machine does not travel forward or backward 1524
H-2 Machine does not travel forward (Machine travels backward normally) 1527
H-3 Machine does not travel backward (Machine travels forward normally) 1528
H-4 Machine does not travel forward or backward fast 1529
H-5 Machine does not travel forward fast (Machine travel backward fast) 1533
H-6 Machine does not travel backward fast (Machine travel forward fast) 1534
H-7 Machine lacks power neither when traveling forward nor backward 1535
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) 1538
H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) 1539
H-10 Engine stalls during travel or engine speed drops significantly 1540
H-11 Steering wheel is too heavy to turn 1541
H-12 Steering wheel is heavy to turn 1543
H-13 Machine sways or large shocks are made while machine turns 1544
H-14 Machine unintentionally turns when machine travels 1545
H-15 Wheel brakes do not work or are weak 1546
H-16 Wheel brakes are not released or drag 1547
H-17 Parking brake does not work or it is weak 1548
H-18 Parking brake is not released or drags 1549
H-19 Boom does not rise 1550
H-20 Boom moves slow or boom lacks lifting force 1552
H-21 Rising boom slows down at certain height 1554
H-22 Lift cylinders do not serve to hold bucket (bucket rises off ground) 1555
H-23 Hydraulic drift of boom is large 1556
H-24 Boom moves up and down during operation 1557
H-25 Bucket does not tilt back 1558
H-26 Bucket moves slow or lacks tilt force 1560
H-27 Bucket decelerates during tilt-back operation 1562
H-28 Bucket cylinder does not hold bucket on ground 1563
H-29 Hydraulic drift of bucket is large 1564
H-30 Bucket tilts back and forth during carrying load 1565
H-31 Boom and bucket control levers do not move smoothly and are heavy to move 1566
H-32 Operating work equipment causes engine speed to lower significantly or engine to stall 1567
H-33 Large shocks are made when work equipment starts to move and stops 1568
H-34 When certain work equipment is relieved hydraulically, other work equipment moves 1569
H-35 E C S S (travel damper) does not work and machine pitches and bounces 1570
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) 1571
H-37 Unusual noise is heard from around fan 1573
Troubleshooting of engine (S-mode) 1574
Information described in troubleshooting table (S mode) 1574
S-1 Engine does not crank when starting switch is turned to START position 1575
S-2 Engine cranks but no exhaust smoke comes out 1576
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1577
S-4 Engine startability is poor 1578
S-5 Engine does not pick up smoothly 1580
S-6 Engine stops during operation 1582
S-7 Engine runs rough or is unstable 1584
S-8 Engine lacks power 1585
S-9 KDPF gets clogged in a short time 1587
S-10 Engine oil consumption is excessive 1589
S-11 Engine oil becomes contaminated early 1590
S-12 Fuel consumption is excessive 1591
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1592
S-14 Oil pressure drops 1593
S-15 Fuel mixes into engine oil 1594
S-16 Water mixes into engine oil (milky) 1595
S-17 Coolant temperature rises too high (overheating) 1596
S-18 Unusual noise is heard 1597
S-19 Vibration is excessive 1598
S-20 Air cannot be bled from fuel circuit 1600
S-21 Active regeneration is executed frequently 1601
S-22 Active regeneration takes time 1602
S-23 White smoke is exhausted during active regeneration 1603
50 Disassembly and assembly 1605
Table of contents 1606
Related information on disassembly and assembly 1608
How to read this manual 1608
Coating materials list 1610
Special tools list 1614
Sketches of special tools 1619
Engine and cooling system 1632
Removal and installation of supply pump assembly 1632
Removal and installation of injector assembly 1635
Removal and installation of cylinder head assembly 1644
Removal and installation of engine hood assembly 1657
Removal and installation of radiator core assembly 1659
Removal and installation of aftercooler 1661
Removal and installation of hydraulic oil cooler 1662
Removal and installation of engine assembly 1663
Removal and installation of engine front oil seal 1671
Removal and installation of engine rear oil seal 1674
Removal and installation of cooling fan and fan motor assembly 1677
Removal and installation of KDPF assembly 1679
Disassembly and assembly of KDPF assembly 1682
Removal and installation of KCCV assembly 1691
Removal and installation of air cleaner assembly 1692
Removal and installation of KVGT assembly 1693
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1696
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 1698
Removal and installation of alternator belt 1700
Removal and installation of fuel tank assembly 1701
Power train 1704
Removal and installation of transfer assembly 1704
Disassembly and assembly of transfer assembly 1708
Removal and installation of front axle assembly 1739
Removal and installation of rear axle assembly 1741
Disassembly and assembly of axle housing assembly 1744
Disassembly and assembly of differential assembly 1756
Undercarriage and frame 1778
Removal and installation of center hinge pin 1778
Removal and installation of counterweight assembly 1787
Hydraulic system 1791
Removal and installation of hydraulic tank assembly 1791
Removal and installation of control valve assembly 1795
Disassembly and assembly of control valve assembly 1799
Removal and installation of hydraulic pump assembly 1802
Removal and installation of HST motor1 assembly 1807
Removal and installation of HST motor2 assembly 1809
Disassembly and assembly of hydraulic cylinder assembly 1811
Work equipment 1818
Removal and installation of work equipment assembly 1818
Cab and its attachments 1824
Removal and installation of operator’s cab and floor frame assembly 1824
Removal and installation of operator’s cab glass (adhered glass) 1829
Removal and installation of operator’s seat assembly 1837
Removal and installation of seat belt 1839
Removal and installation of air conditioner unit assembly 1840
Removal and installation of air conditioner compressor 1845
Removal and installation of air conditioner condenser 1847
Electrical system 1849
Removal and installation of machine monitor assembly 1849
Removal and installation of engine controller assembly 1851
Removal and installation of HST controller assembly 1853
Removal and installation of air conditioner controller assembly 1855
Removal and installation of monitor controller assembly 1856
Removal and installation of mass air flow and temperature sensor 1858
Removal and installation of KOMTRAX terminal assembly 1859
60 Maintenance standard 1861
Table of contents 1862
Engine and cooling system 1863
Engine related parts 1863
Cooling fan motor 1864
Power train 1866
Damper 1866
Transfer 1867
Drive shaft 1874
Axle 1875
Differential 1877
Limited slip differential 1881
Final drive 1883
Steering system 1885
Steering column 1885
Priority valve 1886
Emergency steering valve 1887
Steering cylinder 1888
Brake system 1890
Brake accumulator charge valve 1890
Slack adjuster 1891
Brake 1892
Parking brake 1894
Parking brake solenoid valve 1895
Undercarriage and frame 1896
Axle mount 1896
Center hinge pin 1898
Hydraulic system 1901
Hydraulic tank 1901
Double type gear pump 1902
Steering and work equipment pump 1903
Control valve 1907
Self-pressure reducing valve 1920
Work equipment PPC valve 1922
Work equipment lock solenoid valve 1924
Work equipment 1925
Work equipment linkage 1925
Bucket 1929
Work equipment cylinder 1931
Cab and its attachments 1932
Cab mount 1932
Electrical system 1933
Bucket positioner 1933
Fork positioner 1934
Remote boom positioner 1935
80 Appendix 1937
Table of contents 1938
Air conditioner components 1939
Precautions for refrigerant 1939
Air conditioner component 1940
Configuration and function of refrigeration cycle 1942
Outline of refrigeration cycle 1943
Air conditioner unit 1945
Dual pressure switch 1950
Air conditioner controller 1951
Compressor 1952
Condenser 1953
Receiver drier 1954
Sunlight sensor 1956
Outer temperature sensor (outside air temperature sensor) 1957
Procedure for testing and troubleshooting 1958
Circuit diagram and arrangement of connector pins 1960
System diagram 1963
Parts and connectors layout 1966
Testing with self-diagnosis function 1971
How to open the electrical system abnormality record screen in service mode of the machine monitor 1972
Testing temperature control system 1974
Testing vent (mode) changeover 1976
Testing FRESH/RECIRC air changeover 1978
Testing evaporator temperature sensor 1980
Testing relays 1982
Troubleshooting chart 1 1984
Troubleshooting chart 2 1985
Information in troubleshooting table 1987
Failure code list related to air conditioner 1988
Failure code [879AKA] A/C Inner Sensor Open Circuit 1989
Failure code [879AKB] A/C Inner Sensor Short Circuit 1991
Failure code [879BKA] A/C Outer Sensor Open Circuit 1993
Failure code [879BKB] A/C Outer Sensor Short Circuit 1995
Failure code [879CKA] Ventilating Sensor Open Circuit 1997
Failure code [879CKB] Ventilating Sensor Short Circuit 1999
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 2001
Failure code [879EMC] Ventilation Damper Abnormality 2003
Failure code [879FMC] Air Mix Damper Abnormality 2006
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 2009
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 2012
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2015
A-4 Troubleshooting for FRESH/RECIRC air changeover 2018
Troubleshooting with gauge pressure 2020
Connection of service tool 2023
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 2025
Handling of compressor oil 2027
90 Diagrams and drawings 2029
Table of contents 2030
Hydraulic circuit diagram 2031
Symbols in hydraulic circuit diagram 2031
Hydraulic circuit diagram 2035
Electric circuit diagram 2037
Symbols in electric circuit diagram 2037
Electrical circuit diagram of machine body 2041
Electrical circuit diagram of floor 2051
INDEX 2067

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