Komatsu WA470-7 Wheel Loader Shop Manual SEN06006-09 – PDF DOWNLOAD

Komatsu WA470-7 Wheel Loader Shop Manual SEN06006-09 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA470-7 Wheel Loader Shop Manual SEN06006-09 – PDF DOWNLOAD

Language : English
Pages : 3096
Downloadable : Yes
File Type : PDF
Size: 89.7 MB

DESCRIPTION:

Komatsu WA470-7 Wheel Loader Shop Manual SEN06006-09 – PDF DOWNLOAD

SERIAL NUMBERS 10001 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 WA470-7 Wheel Loader Shop Manual SEN06006-09 – PDF DOWNLOAD

Index
00 Index and foreword 00-1
Foreword, safety and general information 00-19
Important safety notice 00-19
How to read the shop manual 00-26
Explanation of terms for maintenance standard 00-28
Handling equipment of fuel system devices 00-30
Handling of intake system parts 00-31
Handling of hydraulic equipment 00-32
Method of disconnecting and connecting of push-pull type coupler 00-34
Handling of electrical equipment 00-37
How to read electric wire code 00-45
Precautions when performing operation 00-48
Practical use of KOMTRAX 00-53
Standard tightening torque table 00-54
List of abbreviation 00-60
Conversion table 00-65
01 Specification 01-1
Table of contents 01-2
Specifications 01-3
Specification drawing 01-3
Specifications 01-5
Weight table 01-10
Table of fuel, coolant, and lubricants 01-12
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 10-12
EGR system circuit diagram 10-14
EGR valve 10-15
EGR cooler 10-17
KCCV layout drawing 10-19
KCCV ventilator 10-21
KDPF 10-23
Cooling system 10-27
Cooling fan pump 10-30
Cooling fan motor 10-39
Power train 10-46
Power train system 10-46
Drive shaft 10-49
Power train piping drawing 10-50
Transmission control 10-51
Torque converter 10-54
Transmission 10-59
Transmission control valve 10-78
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV 10-81
3rd, 4th clutch ECMV 10-88
Lockup clutch ECMV 10-95
Main relief and torque converter relief valve 10-99
Axle 10-101
Differential 10-103
Final drive 10-113
Steering system 10-115
Layout of steering parts 10-115
Steering column 10-116
Index 00 Index and foreword
00-2 WA470-7
Joystick steering lever linkage 10-117
Steering pump 10-118
Steering valve 10-130
Orbit-roll valve 10-144
Stop valve 10-150
Emergency steering motor 10-151
Emergency steering pump 10-152
Brake system 10-153
Layout of brake parts 10-153
Charge valve 10-155
Brake valve 10-161
Slack adjuster 10-165
Accumulator (for brake) 10-168
Brake 10-169
Parking brake control 10-172
Parking brake 10-173
Parking brake solenoid valve 10-174
Parking brake emergency release valve 10-177
Undercarriage and frame 10-178
Axle mount and center hinge pin 10-178
Tire 10-179
Hydraulic system 10-181
Hydraulic component layout 10-181
Work equipment control 10-183
Hydraulic tank 10-185
Double type gear pump 10-188
Work equipment pump 10-189
Control valve 10-210
CLSS 10-219
Hydraulic circuit diagram and names of valves 10-223
Accumulator charge valve 10-234
Work equipment lock solenoid valve 10-238
Accumulator (for PPC circuit) 10-239
Accumulator (for ECSS) 10-240
Work equipment 10-241
Work equipment linkage 10-241
Bucket 10-242
Bucket positioner and boom positioner 10-243
Cab and its attachments 10-244
ROPS cab 10-244
Electrical system 10-245
Engine control system 10-245
Preheating system 10-247
Engine power mode selector circuit 10-249
Engine output limit function 10-250
Automatic warm-up function 10-251
Parking brake control system 10-252
System operating lamp function 10-254
Battery disconnect switch function 10-256
Transmission controller system 10-258
Work equipment control system 10-283
Machine monitor system 10-302
Rear view monitor system 10-325
KOMTRAX system 10-328
System component parts 10-331
Sensor 10-362
20 STANDARD VALUE TABLE 20-1
Table of contents 20-2
00 Index and foreword Index
WA470-7 00-3
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 20-21
30 TESTING AND ADJUSTING 30-1
Table of contents 30-2
Related information on testing and adjusting 30-4
Tools for testing and adjusting 30-4
Sketch of tools for testing and adjusting 30-8
Engine and cooling system 30-10
Testing engine speed 30-10
Testing boost pressure 30-12
Testing exhaust gas color 30-14
Testing and adjusting valve clearance 30-16
Testing compression pressure 30-18
Testing blowby pressure 30-22
Testing engine oil pressure 30-24
Testing EGR valve and KVGT oil pressures 30-25
Testing fuel pressure 30-26
Testing fuel return rate and leakage 30-27
Bleeding air from fuel system 30-31
Testing fuel circuit for leakage 30-33
Handling cylinder cutout mode operation 30-34
Handling no-injection cranking operation 30-35
Testing of KDPF and muffler stack for looseness and damage 30-36
Testing of installed condition of cylinder heads and manifolds 30-37
Testing engine piping for damage and looseness 30-38
Testing and adjusting air conditioner compressor belt tension 30-39
Testing and adjusting alternator belt tension 30-41
Procedures for cleaning fuel doser 30-43
Writing compensation values at replacement of injector and engine controller 30-46
Writing compensation amount for soot accumulation caused by ash on engine controller 30-50
Power train 30-52
Adjusting transmission output speed sensor 30-52
Adjusting transmission input speed sensor 30-53
Flushing procedure for torque converter and transmission hydraulic circuit 30-54
Retrieval of disabled machine due to transmission valve failure 30-56
Testing oil leakage from axle final drive 30-58
Testing drive shaft for looseness, backlash, and damage 30-59
Testing and adjusting power train oil pressure 30-60
Steering system 30-75
Testing directional lever 30-75
Testing steering wheel 30-76
Testing work equipment control lever 30-78
Testing and adjusting steering circuit oil pressure 30-80
Bleeding air from steering cylinder circuit 30-83
Testing and adjusting steering stopper valve 30-84
Brake system 30-85
Testing brake pedal 30-85
Testing and adjusting brake pedal linkage 30-86
Testing braking performance 30-87
Testing and adjusting of accumulator charge pressure 30-88
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake accumulator with
nitrogen gas 30-90
Testing wheel brake oil pressure 30-94
Testing lowering of wheel brake pressure 30-96
Testing wear of wheel brake disc 30-98
Bleeding air from wheel brake circuit 30-99
Index 00 Index and foreword
00-4 WA470-7
Releasing remaining pressure in brake accumulator circuit 30-101
Testing parking brake performance 30-102
Testing parking brake oil pressure 30-103
Testing wear of parking brake disc 30-104
Method of releasing parking brake manually 30-105
Hydraulic system 30-107
Testing cooling fan speed 30-107
Testing cooling fan pump circuit oil pressure 30-108
Bleeding air from hydraulic fan circuit 30-110
Testing and adjusting work equipment EPC oil pressure 30-112
Testing and adjusting work equipment oil pressure 30-115
Bleeding air from work equipment circuit 30-119
Releasing remaining pressure from work equipment circuit 30-120
Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen
gas 30-121
Work equipment 30-125
Testing and adjusting bucket position detection lever 30-125
Testing and adjusting boom position detection lever 30-126
Electrical system 30-127
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 30-127
Special functions of machine monitor 30-129
Adjusting rearview camera angle 30-218
Handling voltage circuit of engine controller 30-219
Handling battery disconnect switch 30-220
Testing diodes 30-221
Pm clinic 30-222
Pm Clinic service 30-222
Check sheet 30-223
40 Troubleshooting 40-1
Table of contents 40-2
Related information on troubleshooting 40-12
Troubleshooting points 40-12
Sequence of events in troubleshooting 40-14
Check before troubleshooting 40-16
Inspection procedure before troubleshooting 40-18
Preparation work for troubleshooting of electrical system 40-35
Classification and procedures for troubleshooting 40-41
Symptom and troubleshooting numbers 40-44
Information in troubleshooting table 40-47
Connector list and layout 40-49
Connector contact identification 40-188
T-branch box and T-branch adapter table 40-227
Fuse location table 40-232
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 40-235
Precautions when performing troubleshooting of machine monitor 40-238
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit 40-240
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 40-245
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 40-246
Failure codes table 40-247
Troubleshooting by failure code (display of code) 40-262
Failure code [1500L0] 40-262
Failure code [15SAL1] 40-263
Failure code [15SALH] 40-265
Failure code [15SBL1] 40-267
Failure code [15SBLH] 40-269
Failure code [15SEL1] 40-271
Failure code [15SELH] 40-273
Failure code [15SFL1] 40-275
00 Index and foreword Index
WA470-7 00-5
Failure code [15SFLH] 40-277
Failure code [15SGL1] 40-279
Failure code [15SGLH] 40-281
Failure code [15SHL1] 40-283
Failure code [15SHLH] 40-285
Failure code [2F00MA] 40-287
Failure code [2G42ZG] 40-291
Failure code [2G43ZG] 40-293
Failure code [879AKA] 40-295
Failure code [879AKB] 40-296
Failure code [879BKA] 40-297
Failure code [879BKB] 40-298
Failure code [879CKA] 40-299
Failure code [879CKB] 40-300
Failure code [879DKZ] 40-301
Failure code [879EMC] 40-302
Failure code [879FMC] 40-303
Failure code [989A00] 40-304
Failure code [989L00] 40-305
Failure code [989M00] 40-306
Failure code [989N00] 40-307
Failure code [A1U0N3] 40-308
Failure code [A1U0N4] 40-310
Failure code [AA10NX] 40-312
Failure code [AB00KE] 40-314
Failure code [AB00KY] 40-316
Failure code [B@BAZG] 40-317
Failure code [B@BAZK] 40-318
Failure code [B@BCNS] 40-320
Failure code [B@BCZK] 40-321
Failure code [B@C7NS] 40-323
Failure code [B@CENS] 40-325
Failure code [B@HANS] 40-326
Failure code [CA115] 40-327
Failure code [CA122] 40-328
Failure code [CA123] 40-330
Failure code [CA131] 40-332
Failure code [CA132] 40-334
Failure code [CA135] 40-336
Failure code [CA141] 40-338
Failure code [CA144] 40-340
Failure code [CA145] 40-342
Failure code [CA153] 40-344
Failure code [CA154] 40-346
Failure code [CA187] 40-348
Failure code [CA221] 40-350
Failure code [CA222] 40-352
Failure code [CA227] 40-354
Failure code [CA234] 40-355
Failure code [CA238] 40-356
Failure code [CA239] 40-357
Failure code [CA271] 40-358
Failure code [CA272] 40-359
Failure code [CA273] 40-360
Failure code [CA274] 40-361
Failure code [CA322] 40-362
Failure code [CA323] 40-364
Failure code [CA324] 40-366
Index 00 Index and foreword
00-6 WA470-7
Failure code [CA325] 40-368
Failure code [CA331] 40-370
Failure code [CA332] 40-372
Failure code [CA343] 40-374
Failure code [CA351] 40-375
Failure code [CA352] 40-376
Failure code [CA356] 40-378
Failure code [CA357] 40-380
Failure code [CA386] 40-382
Failure code [CA431] 40-383
Failure code [CA432] 40-386
Failure code [CA441] 40-389
Failure code [CA442] 40-391
Failure code [CA449] 40-392
Failure code [CA451] 40-393
Failure code [CA452] 40-395
Failure code [CA515] 40-397
Failure code [CA516] 40-399
Failure code [CA553] 40-401
Failure code [CA555] 40-402
Failure code [CA556] 40-403
Failure code [CA559] 40-404
Failure code [CA595] 40-408
Failure code [CA687] 40-409
Failure code [CA689] 40-411
Failure code [CA691] 40-413
Failure code [CA692] 40-415
Failure code [CA697] 40-417
Failure code [CA698] 40-418
Failure code [CA731] 40-419
Failure code [CA778] 40-420
Failure code [CA1117] 40-422
Failure code [CA1664] 40-423
Failure code [CA1691] 40-426
Failure code [CA1695] 40-429
Failure code [CA1696] 40-431
Failure code [CA1843] 40-433
Failure code [CA1844] 40-435
Failure code [CA1879] 40-437
Failure code [CA1881] 40-439
Failure code [CA1883] 40-441
Failure code [CA1921] 40-444
Failure code [CA1922] 40-447
Failure code [CA1923] 40-452
Failure code [CA1924] 40-454
Failure code [CA1925] 40-456
Failure code [CA1927] 40-458
Failure code [CA1928] 40-460
Failure code [CA1942] 40-462
Failure code [CA1963] 40-463
Failure code [CA1977] 40-467
Failure code [CA1993] 40-469
Failure code [CA2185] 40-471
Failure code [CA2186] 40-473
Failure code [CA2249] 40-475
Failure code [CA2265] 40-476
Failure code [CA2266] 40-478
Failure code [CA2271] 40-480
00 Index and foreword Index
WA470-7 00-7
Failure code [CA2272] 40-482
Failure code [CA2349] 40-484
Failure code [CA2353] 40-486
Failure code [CA2357] 40-488
Failure code [CA2381] 40-489
Failure code [CA2382] 40-491
Failure code [CA2383] 40-493
Failure code [CA2386] 40-495
Failure code [CA2387] 40-497
Failure code [CA2555] 40-498
Failure code [CA2556] 40-500
Failure code [CA2637] 40-502
Failure code [CA2639] 40-504
Failure code [CA2732] 40-507
Failure code [CA2733] 40-509
Failure code [CA2741] 40-511
Failure code [CA2765] 40-512
Failure code [CA2878] 40-513
Failure code [CA2881] 40-516
Failure code [CA3133] 40-521
Failure code [CA3134] 40-523
Failure code [CA3135] 40-525
Failure code [CA3167] 40-528
Failure code [CA3251] 40-531
Failure code [CA3253] 40-534
Failure code [CA3254] 40-537
Failure code [CA3255] 40-540
Failure code [CA3256] 40-544
Failure code [CA3311] 40-547
Failure code [CA3312] 40-551
Failure code [CA3313] 40-554
Failure code [CA3314] 40-557
Failure code [CA3315] 40-561
Failure code [CA3316] 40-566
Failure code [CA3317] 40-569
Failure code [CA3318] 40-573
Failure code [CA3319] 40-578
Failure code [CA3321] 40-582
Failure code [CA3322] 40-585
Failure code [CA3419] 40-590
Failure code [CA3421] 40-592
Failure code [D150KA] 40-594
Failure code [D150KB] 40-596
Failure code [D150KY] 40-598
Failure code [D160KA] 40-600
Failure code [D160KB] 40-603
Failure code [D160KY] 40-606
Failure code [D191KA] 40-609
Failure code [D191KB] 40-611
Failure code [D191KY] 40-613
Failure code [D192KA] 40-615
Failure code [D192KB] 40-617
Failure code [D192KY] 40-618
Failure code [D193KA] 40-619
Failure code [D193KB] 40-621
Failure code [D193KY] 40-623
Failure code [D193MC] 40-625
Failure code [D19JKZ] 40-627
Index 00 Index and foreword
00-8 WA470-7
Failure code [D1E6KA] 40-629
Failure code [D1E6KB] 40-631
Failure code [D1E6KY] 40-633
Failure code [D5ZHKA] 40-635
Failure code [D5ZHKB] 40-637
Failure code [D5ZHKZ] 40-639
Failure code [D5ZHL6] 40-641
Failure code [D811MC] 40-643
Failure code [D862KA] 40-644
Failure code [D8ALKA] 40-645
Failure code [D8ALKB] 40-647
Failure code [D8AQK4] 40-649
Failure code [D8AQKR] 40-650
Failure code [DAF0KT] 40-652
Failure code [DAF0MB] 40-653
Failure code [DAF0MC] 40-654
Failure code [DAF3KK] 40-655
Failure code [DAF8KB] 40-657
Failure code [DAFDKB] 40-658
Failure code [DAFGMC] 40-660
Failure code [DAFLKA] 40-661
Failure code [DAFLKB] 40-663
Failure code [DAFQKR] 40-665
Failure code [DAQ0KK] 40-666
Failure code [DAQ0KT] 40-669
Failure code [DAQ0MC] 40-670
Failure code [DAQ1KA] 40-671
Failure code [DAQ2KK] 40-673
Failure code [DAQ4KB] 40-676
Failure code [DAQ9KQ] 40-678
Failure code [DAQLKA] 40-679
Failure code [DAQLKB] 40-681
Failure code [DAQQKR] 40-683
Failure code [DAQRKR] 40-684
Failure code [DAQRMA] 40-685
Failure code [DAZ9KQ] 40-686
Failure code [DAZQKR] 40-687
Failure code [DB2QKR] 40-688
Failure code [DB2RKR] 40-693
Failure code [DB90KK] 40-698
Failure code [DB90KT] 40-700
Failure code [DB90MC] 40-701
Failure code [DB91KA] 40-702
Failure code [DB92KK] 40-704
Failure code [DB95KX] 40-706
Failure code [DB96KX] 40-710
Failure code [DB99KQ] 40-714
Failure code [DB9LKA] 40-715
Failure code [DB9LKB] 40-717
Failure code [DB9QKR] 40-719
Failure code [DB9RKR] 40-720
Failure code [DB9RMA] 40-721
Failure code [DBE5KX] 40-722
Failure code [DBE6KX] 40-724
Failure code [DD1ALD] 40-726
Failure code [DDAAL6] 40-730
Failure code [DDB6L4] 40-732
Failure code [DDD1LD] 40-735
00 Index and foreword Index
WA470-7 00-9
Failure code [DDK3KA] 40-739
Failure code [DDK3KB] 40-744
Failure code [DDK4KA] 40-748
Failure code [DDK4KB] 40-751
Failure code [DDK5L4] 40-753
Failure code [DDK6KA] 40-755
Failure code [DDK6KB] 40-758
Failure code [DDNRKY] 40-760
Failure code [DDT0L4] 40-764
Failure code [DDT4LD] 40-768
Failure code [DDT9LD] 40-772
Failure code [DDW9LD] 40-776
Failure code [DDWLLD] 40-780
Failure code [DF10KA] 40-784
Failure code [DF10KB] 40-786
Failure code [DGF1KA] 40-789
Failure code [DGF1KB] 40-791
Failure code [DGH2KX] 40-793
Failure code [DGR2KB] 40-795
Failure code [DGR2KZ] 40-796
Failure code [DGT1KA] 40-798
Failure code [DGT1KB] 40-801
Failure code [DH21KA] 40-803
Failure code [DH21KB] 40-805
Failure code [DHA4KA] 40-807
Failure code [DHPCKX] 40-809
Failure code [DHPDKX] 40-811
Failure code [DHT1KX] 40-813
Failure code [DHT5KX] 40-815
Failure code [DHT7KX] 40-817
Failure code [DHT8KA] 40-819
Failure code [DHT8KB] 40-821
Failure code [DHT8ZG] 40-823
Failure code [DHUDKA] 40-824
Failure code [DHUDKB] 40-826
Failure code [DJF1KA] 40-828
Failure code [DK55KA] 40-830
Failure code [DK55KY] 40-833
Failure code [DK55L5] 40-835
Failure code [DK59KA] 40-836
Failure code [DK59KY] 40-841
Failure code [DK59L8] 40-846
Failure code [DK5AKA] 40-853
Failure code [DK5AKY] 40-859
Failure code [DK5BKA] 40-864
Failure code [DK5BKY] 40-869
Failure code [DK5BL8] 40-874
Failure code [DK5CKA] 40-881
Failure code [DK5CKY] 40-886
Failure code [DK5DKA] 40-891
Failure code [DK5DKY] 40-896
Failure code [DK5DL8] 40-900
Failure code [DK5EKA] 40-906
Failure code [DK5EKY] 40-911
Failure code [DK5FKA] 40-915
Failure code [DK5FKY] 40-918
Failure code [DK5FL8] 40-921
Failure code [DK5GKA] 40-925
Index 00 Index and foreword
00-10 WA470-7
Failure code [DK5GKY] 40-928
Failure code [DKA0KA] 40-931
Failure code [DKA0KY] 40-933
Failure code [DKA0L0] 40-935
Failure code [DKA1KA] 40-937
Failure code [DKA1KY] 40-939
Failure code [DLF1KA] 40-941
Failure code [DLF1LC] 40-943
Failure code [DLM3KA] 40-945
Failure code [DLM3LC] 40-947
Failure code [DLT3KA] 40-949
Failure code [DLT3LC] 40-951
Failure code [DPQ1KR] 40-953
Failure code [DPQ2KR] 40-956
Failure code [DPQ3KR] 40-959
Failure code [DSJ0KR] 40-962
Failure code [DT20KB] 40-964
Failure code [DT22KB] 40-968
Failure code [DV00KB] 40-972
Failure code [DW4PKA] 40-974
Failure code [DW4PKB] 40-976
Failure code [DW4PKY] 40-978
Failure code [DW4QKA] 40-980
Failure code [DW4QKB] 40-982
Failure code [DW4QKY] 40-984
Failure code [DW4RKA] 40-986
Failure code [DW4RKB] 40-988
Failure code [DW4RKY] 40-990
Failure code [DW4SKA] 40-992
Failure code [DW4SKB] 40-994
Failure code [DW4SKY] 40-996
Failure code [DW7BKA] 40-998
Failure code [DW7BKB] 40-1000
Failure code [DW7BKY] 40-1002
Failure code [DWM1KA] 40-1003
Failure code [DWM1KB] 40-1005
Failure code [DWM1KY] 40-1007
Failure code [DWN6KA] 40-1009
Failure code [DWN6KB] 40-1013
Failure code [DWN6KY] 40-1017
Failure code [DWN8KA] 40-1021
Failure code [DWN8KB] 40-1025
Failure code [DWN8KY] 40-1029
Failure code [DX16KA] 40-1033
Failure code [DX16KB] 40-1035
Failure code [DX16KY] 40-1037
Failure code [DXA1KA] 40-1039
Failure code [DXA1KB] 40-1041
Failure code [DXA1KY] 40-1043
Failure code [DXANKA] 40-1045
Failure code [DXANKB] 40-1047
Failure code [DXANKY] 40-1049
Failure code [DXH1KA] 40-1050
Failure code [DXH1KB] 40-1052
Failure code [DXH1KY] 40-1054
Failure code [DXH4KA] 40-1056
Failure code [DXH4KB] 40-1058
Failure code [DXH4KY] 40-1060
00 Index and foreword Index
WA470-7 00-11
Failure code [DXH5KA] 40-1062
Failure code [DXH5KB] 40-1064
Failure code [DXH5KY] 40-1066
Failure code [DXH6KA] 40-1068
Failure code [DXH6KB] 40-1070
Failure code [DXH6KY] 40-1072
Failure code [DXH7KA] 40-1074
Failure code [DXH7KB] 40-1076
Failure code [DXH7KY] 40-1078
Failure code [DXH8KA] 40-1080
Failure code [DXH8KB] 40-1082
Failure code [DXH8KY] 40-1084
Failure code [DXHHKA] 40-1086
Failure code [DXHHKB] 40-1088
Failure code [DXHHKY] 40-1090
Failure code [DXHJKA] 40-1092
Failure code [DXHJKB] 40-1094
Failure code [DXHJKY] 40-1096
Failure code [DXHKKA] 40-1098
Failure code [DXHKKB] 40-1100
Failure code [DXHKKY] 40-1102
Failure code [DXHLKA] 40-1104
Failure code [DXHLKB] 40-1106
Failure code [DXHLKY] 40-1108
Failure code [DXHMKA] 40-1110
Failure code [DXHMKB] 40-1112
Failure code [DXHMKY] 40-1114
Failure code [DY30MA] 40-1116
Failure code [DY30MC] 40-1119
Failure code [DY30ME] 40-1123
Failure code [LA00L3] 40-1125
Troubleshooting of electrical system (E-mode) 40-1126
E-1 The engine does not start 40-1126
E-2 Manual preheating system does not work 40-1132
E-3 Automatic preheating system does not work 40-1135
E-4 While preheating is working, preheating monitor does not light up 40-1137
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing 40-1139
E-6 LCD unit on machine monitor displays nothing 40-1142
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) 40-1144
E-8 LCD on machine monitor does not display properly 40-1146
E-9 Meter unit display on machine monitor is abnormal 40-1148
E-10 Night lighting lamp of meter unit on machine monitor is abnormal 40-1151
E-11 Caution LED on machine monitor is abnormal 40-1154
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly
40-1156
E-13 2 switches operation of switch panel on machine monitor does not function 40-1158
E-14 Switch panel buzzer of machine monitor is abnormal 40-1161
E-15 Rear view monitor does not light up or backlight flickers 40-1163
E-16 Rear view monitor images are not displayed clearly 40-1166
E-17 Rear view monitor brightness cannot be adjusted 40-1169
E-18 Night lighting lamp of rearview monitor is abnormal 40-1172
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly 40-1174
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position
40-1175
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light
40-1179
E-22 Air cleaner clogging indicator lamp does not light up 40-1181
E-23 Radiator coolant level caution lamp does not light up 40-1182
Index 00 Index and foreword
00-12 WA470-7
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution
lamp does not light 40-1184
E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil
temperature caution lamp does not light up 40-1186
E-26 Fuel level gauge does not indicate correct level 40-1187
E-27 Seat belt caution lamp indication is abnormal 40-1189
E-28 Horn does not sound 40-1190
E-29 Horn does not stop sounding 40-1193
E-30 Alarm buzzer does not sound 40-1195
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding 40-1196
E-32 Kickdown does not work when kickdown switch is turned on 40-1197
E-33 Hold switch does not work when it is pressed 40-1199
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 40-1201
E-35 Transmission cut-off mode is not selected or not released 40-1204
E-36 Transmission cut-off setting cannot be released 40-1206
E-37 Directional selector (FNR) switch mode is not selected or not released 40-1208
E-38 When operating engine power mode selector switch, engine mode selector function does not operate
properly 40-1210
E-39 Flow of loader pump does not increase from the minimum rate 40-1212
E-40 ECSS function cannot be selected or cannot be released 40-1213
E-41 None of headlamp, clearance lamp, and tail lamp light up 40-1215
E-42 Clearance lamp and tail lamp do not light up or go out 40-1218
E-43 Both “high and low beams” of headlamp do not light up or go out 40-1222
E-44 “Low beam” of head lamp does not light up or go out 40-1227
E-45 “High beam” of headlamp does not light up or go out 40-1230
E-46 Front working lamp does not light up or go out 40-1233
E-47 Rear working lamp does not light up or go out 40-1237
E-48 All of turn signal lamps and hazard lamps do not light up or go out 40-1240
E-49 Turn signal lamps do not light up or go out 40-1244
E-50 Hazard lamp does not light up or go out 40-1249
E-51 Brake lamp does not light or stays lighted 40-1254
E-52 Backup lamp does not light up or does not go out 40-1258
E-53 Backup buzzer does not sound or continues to sound 40-1263
E-54 Front wiper does not operate 40-1266
E-55 Rear wiper does not operate 40-1269
E-56 Window washer does not operate 40-1271
E-57 Fuel feed pump does not operate or stop automatically 40-1274
E-58 Fan does not rotate in reverse 40-1276
E-59 Fan remains rotated in reverse 40-1277
E-60 KOMTRAX system does not operate normally 40-1278
Troubleshooting of hydraulic and mechanical systems (H-mode) 40-1280
Information mentioned in troubleshooting table (H-mode) 40-1280
System chart of hydraulic and mechanical systems 40-1281
Failure mode and cause table 40-1284
H-1 Machine does not start 40-1291
H-2 Torque converter lockup pressure cannot be released (engine stalls) 40-1294
H-3 Torque converter lockup clutch does not engage 40-1295
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift
40-1296
H-5 Large shock is made when machine moves off or gear is shifted 40-1299
H-6 Large time lag is observed when machine starts and gear is shifted 40-1301
H-7 Oil temperature of torque converter is high 40-1303
H-8 Machine does not turn 40-1305
H-9 Turning response is poor 40-1309
H-10 Steering wheel is heavy to turn 40-1313
H-11 Machine sways or large shocks are made while machine turns 40-1314
H-12 Turning radius differs between right and left turns 40-1317
00 Index and foreword Index
WA470-7 00-13
H-13 Wheel brakes do not work or are weak 40-1318
H-14 Wheel brakes are not released or drag 40-1320
H-15 Parking brake does not work or it is weak 40-1321
H-16 Parking brake is not released or drags (including emergency release system) 40-1322
H-17 Boom does not rise 40-1323
H-18 Boom moves slow or boom lacks lifting force 40-1325
H-19 Rising boom slows down at certain height 40-1327
H-20 Lift cylinders do not serve to hold bucket on ground 40-1328
H-21 Hydraulic drift of boom is large 40-1329
H-22 Boom moves up and down during operation 40-1330
H-23 Bucket does not tilt back 40-1331
H-24 Bucket moves slow or lacks tilt-back force 40-1333
H-25 Bucket decelerates during tilt-back operation 40-1335
H-26 Bucket cylinder does not hold bucket on ground 40-1336
H-27 Hydraulic drift of bucket is large 40-1337
H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) 40-1338
H-29 Boom and bucket control levers do not move smoothly and are heavy to move 40-1339
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall 40-1341
H-31 Large shocks are made when work equipment starts to move and stops 40-1342
H-32 When certain work equipment stalls hydraulically, other work equipment moves 40-1344
H-33 E C S S (travel damper) does not work and machine pitches and bounces 40-1345
H-34 Bucket does not stop at the position which is set with remote bucket positioner 40-1346
H-35 Fan speed is abnormal (too high or low, or fan does not rotate) 40-1347
H-36 Unusual noise is heard from around fan 40-1348
Troubleshooting of engine (S-mode) 40-1349
Information mentioned in troubleshooting table (S-mode) 40-1349
S-1 Engine does not crank when starting switch is turned to start position 40-1350
S-2 Engine cranks but no exhaust smoke comes out 40-1351
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does
not) 40-1352
S-4 Engine startability is poor 40-1353
S-5 Engine does not pick up smoothly 40-1355
S-6 Engine stops during operation 40-1357
S-7 Engine runs rough or is unstable 40-1359
S-8 Engine lacks power 40-1360
S-9 KDPF gets clogged in a short time 40-1362
S-10 Engine oil consumption is excessive 40-1364
S-11 Oil becomes contaminated quickly 40-1365
S-12 Fuel consumption is excessive 40-1366
S-13 Oil is in coolant (Or coolant spurts back or coolant level goes down) 40-1367
S-14 Oil pressure drops 40-1368
S-15 Fuel mixes into engine oil 40-1369
S-16 Water mixes into engine oil (milky) 40-1370
S-17 Coolant temperature rises too high (overheating) 40-1371
S-18 Unusual noise is heard 40-1372
S-19 Vibration is excessive 40-1373
S-20 Air cannot be bled from fuel circuit 40-1374
S-21 Active regeneration is executed frequently 40-1375
S-22 Active regeneration takes time 40-1376
S-23 White smoke is exhausted during active regeneration 40-1377
50 Disassembly and assembly 50-1
Table of contents 50-2
Related information on disassembly and assembly 50-6
How to read this manual 50-6
Coating materials list 50-8
Special tools list 50-12
Sketches of special tools 50-26
Engine and cooling system 50-55
Index 00 Index and foreword
00-14 WA470-7
Removal and installation of supply pump assembly 50-55
Removal and installation of injector assembly 50-66
Removal and installation of fuel doser assembly 50-80
Removal and installation of cylinder head assembly 50-84
Removal and installation of engine hood assembly 50-124
Removal and installation of grille assembly 50-133
Removal and installation of cooling assembly 50-142
Removal and installation of radiator core assembly 50-151
Removal and installation of aftercooler 50-157
Removal and installation of hydraulic oil cooler 50-165
Removal and installation of power train oil cooler assembly 50-172
Removal and installation of engine assembly 50-187
Removal and installation of engine front oil seal 50-205
Removal and installation of engine rear oil seal 50-211
Removal and installation of cooling fan and cooling fan motor assembly 50-219
Removal and installation of KDPF assembly 50-225
Disassembly and assembly of KDPF assembly 50-235
Removal and installation of bellows pipe assembly 50-248
Removal and installation of KCCV assembly 50-259
Removal and installation of VGT assembly 50-264
Removal and installation of EGR valve assembly 50-282
Removal and installation of EGR cooler assembly 50-286
Removal and installation of air cleaner assembly 50-292
Removal and installation of air conditioner compressor belt 50-296
Removal and installation of alternator belt 50-299
Removal and installation of fuel tank assembly 50-302
Power train 50-311
Removal and installation of torque converter and transmission assembly 50-311
Disassembly and assembly of transmission assembly 50-331
Disassembly and assembly of torque converter assembly 50-378
Disassembly and assembly of transmission clutch pack assembly 50-390
Removal and installation of front axle assembly 50-427
Removal and installation of rear axle assembly 50-432
Disassembly and assembly of axle housing assembly 50-446
Disassembly and assembly of differential assembly 50-460
Steering system 50-489
Removal and installation of steering valve assembly 50-489
Brake system 50-495
Removal and installation of brake charge valve assembly 50-495
Removal and installation of parking brake disc and plate 50-499
Undercarriage and frame 50-507
Removal and installation of center hinge pin 50-507
Removal and installation of counterweight assembly 50-521
Removal and installation of full-length fender assembly 50-529
Hydraulic system 50-531
Removal and installation of hydraulic tank assembly 50-531
Removal and installation of control valve assembly 50-540
Removal and installation of steering pump and power train pump assembly 50-548
Removal and installation of work equipment pump and cooling fan pump assembly 50-555
Disassembly and assembly of hydraulic cylinder assembly 50-561
Work equipment 50-571
Removal and installation of work equipment assembly 50-571
Cab and its attachments 50-584
Removal and installation of operator’s cab and floor frame assembly 50-584
Removal and installation of operator’s cab glass (adhered glass) 50-598
Removal and installation of operator’s seat assembly 50-609
Removal and installation of seat belt 50-613
Removal and installation of air conditioner unit assembly 50-615
00 Index and foreword Index
WA470-7 00-15
Removal and installation of air conditioner compressor assembly 50-635
Removal and installation of air conditioner condenser assembly 50-639
Electrical system 50-642
Removal and installation of machine monitor assembly 50-642
Removal and installation of engine controller assembly 50-646
Removal and installation of work equipment controller assembly 50-650
Removal and installation of transmission controller assembly 50-654
Removal and installation of monitor controller assembly 50-656
Removal and installation of mass air flow and temperature sensor 50-661
Removal and installation of KOMTRAX terminal assembly 50-663
60 Maintenance standard 60-1
Table of contents 60-2
Engine and cooling system 60-3
Engine related parts 60-3
Cooling fan pump 60-4
Cooling fan motor 60-7
Power train 60-9
Drive shaft 60-9
Torque converter 60-10
Transmission 60-12
Transmission control valve 60-21
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV 60-23
3rd, 4th clutch ECMV 60-24
Lockup clutch ECMV 60-25
Main relief and torque converter relief valve 60-26
Axle 60-27
Differential 60-29
Final drive 60-39
Steering system 60-41
Steering column 60-41
Steering pump 60-42
Steering valve 60-46
Steering cylinder 60-48
Emergency steering pump 60-51
Brake system 60-52
Charge valve 60-52
Slack adjuster 60-54
Brake 60-55
Parking brake 60-57
Parking brake solenoid valve 60-58
Undercarriage and frame 60-59
Axle mount and center hinge pin 60-59
Hydraulic system 60-64
Hydraulic tank 60-64
Double type gear pump 60-65
Work equipment pump 60-66
Control valve 60-68
Work equipment 60-77
Work equipment linkage 60-77
Bucket 60-81
Work equipment cylinder 60-82
80 Appendix 80-1
Table of contents 80-2
Air conditioner components 80-3
Precautions for refrigerant 80-3
Air conditioner components 80-4
Configuration and function of refrigeration cycle 80-6
Outline of refrigeration cycle 80-7
Index 00 Index and foreword
00-16 WA470-7
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
Check 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
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 90-4
Symbols in hydraulic circuit diagram 90-4
Hydraulic circuit diagram (Steering wheel specifications) 90-9
Hydraulic circuit diagram (Boom RAISE, back tilt) 90-11
Hydraulic circuit diagram (Boom LOWER, turn left, left brake) 90-13
Hydraulic circuit diagram (Joystick steering specifications) 90-15
Hydraulic circuit diagram of power train 90-17
Electric circuit diagram 90-19
Symbols in electric circuit diagram 90-19
Electrical circuit diagram of machine body (1/5) 90-23
Electrical circuit diagram of machine body (2/5) 90-25
Electrical circuit diagram of machine body (3/5) 90-27
Electrical circuit diagram of machine body (4/5) 90-29
Electrical circuit diagram of machine body (5/5) 90-31
00 Index and foreword Index
WA470-7 00-17
Electrical circuit diagram of floor (1/8) 90-33
Electrical circuit diagram of floor (2/8) 90-35
Electrical circuit diagram of floor (3/8) 90-37
Electrical circuit diagram of floor (4/8) 90-39
Electrical circuit diagram of floor (5/8) 90-41
Electrical circuit diagram of floor (6/8) 90-43
Electrical circuit diagram of floor (7/8) 90-45
Electrical circuit diagram of floor (8/8) 90-47
Electrical circuit diagram of floor (EU specifications) (1/8) 90-49
Electrical circuit diagram of floor (EU specifications) (2/8) 90-51
Electrical circuit diagram of floor (EU specifications) (3/8) 90-53
Electrical circuit diagram of floor (EU specifications) (4/8) 90-55
Electrical circuit diagram of floor (EU specifications) (5/8) 90-57
Electrical circuit diagram of floor (EU specifications) (6/8) 90-59
Electrical circuit diagram of floor (EU specifications) (7/8) 90-61
Electrical circuit diagram of floor (EU specifications) (8/8) 90-63
Wiring harness diagram 90-65
Wiring harness diagram (1/30) 90-67
Wiring harness diagram (2/30) 90-69
Wiring harness diagram (3/30) 90-71
Wiring harness diagram (4/30) 90-73
Wiring harness diagram (5/30) 90-75
Wiring harness diagram (6/30) 90-77
Wiring harness diagram (7/30) 90-79
Wiring harness diagram (8/30) 90-81
Wiring harness diagram (9/30) 90-83
Wiring harness diagram (10/30) 90-85
Wiring harness diagram (11/30) 90-87
Wiring harness diagram (12/30) 90-89
Wiring harness diagram (13/30) 90-91
Wiring harness diagram (14/30) 90-93
Wiring harness diagram (15/30) 90-95
Wiring harness diagram (16/30) 90-97
Wiring harness diagram (17/30) 90-99
Wiring harness diagram (18/30) 90-101
Wiring harness diagram (19/30) 90-103
Wiring harness diagram (20/30) 90-105
Wiring harness diagram (21/30) 90-107
Wiring harness diagram (22/30) 90-109
Wiring harness diagram (23/30) 90-111
Wiring harness diagram (24/30) 90-113
Wiring harness diagram (25/30) 90-115
Wiring harness diagram (26/30) 90-117
Wiring harness diagram (27/30) 90-119
Wiring harness diagram (28/30) 90-121
Wiring harness diagram (29/30) 90-123
Wiring harness diagram (30/30) 90-125
INDEX 1

IMAGES PREVIEW OF THE MANUAL: