Komatsu Wheel Loader WA270 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA270, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA270 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM027600 - Wheel Loader WA270-7 Shop Manual.pdf
CEBM031301 - Wheel Loader WA270-8 Shop Manual.pdf
SEN06255-01 - Wheel Loader WA270-7 Shop Manual.pdf
SEN06255-02 - Wheel Loader WA270-7 Shop Manual.pdf
TEN00617-01 - Wheel Loader WA270-7 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 5,443 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEBM027600 - Wheel Loader WA270-7 Shop Manual...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 ...133
Power train system ...133
Layout of power train parts ...135
Damper ...136
HST pump ...137
HST motor1 ...150
HST motor2 ...152
Transfer ...157
Clutch solenoid valve ...164
Drive shaft ...166
Axle ...167
Differential ...169
Torque proportional differential ...173
Limited slip differential ...175
Final drive ...180
Steering system ...183
Layout of steering devices ...183
Steering column ...184
Priority valve ...185
Cushion valve ...189
Emergency steering valve ...190
Orbitrol valve ...193
2way restrictor valve ...199
Brake system ...200
Layout of brake parts ...200
Brake accumulator charge valve ...202
Brake valve ...207
Brake accumulator ...211
Slack adjuster ...212
Brake ...214
Parking brake control ...217
Parking brake ...218
Parking brake solenoid valve ...219
Undercarriage and frame ...221
Axle mount ...221
Center hinge pin ...223
Tire ...224
Hydraulic system ...226
Hydraulic component layout ...226
Work equipment control ...228
Hydraulic tank ...229
Double type gear pump ...232
Steering and work equipment pump ...233
Control valve ...245
CLSS ...255
Hydraulic circuit diagram and names of valves ...259
Self-pressure reducing valve ...272
Work equipment PPC valve ...277
Work equipment lock solenoid valve ...285
PPC circuit accumulator ...286
ECSS accumulator ...287
Work equipment ...288
Work equipment linkage ...288
Bucket ...289
Cab and its attachments ...290
ROPS cab ...290
Cab mount ...292
Electrical system ...293
Engine control system ...293
Preheating system ...296
Engine output limit function ...298
Automatic warm-up function ...299
Parking brake control system ...300
System operating lamp function ...304
Battery disconnect switch function ...305
HST controller system ...307
Machine monitor system ...347
Rearview monitor system ...368
KOMTRAX system ...371
System component parts ...374
Sensor ...397
20 Standard value tables ...417
Table of contents ...418
Standard service value table ...419
Standard value table for engine ...419
Standard value table for machine ...421
Standard value table for electrical system ...433
30 Testing and adjusting ...443
Table of contents ...444
Related information on testing and adjusting ...446
Tools for testing and adjusting ...446
Sketch of tools for testing and adjusting ...452
Engine and cooling system ...453
Testing engine speed ...453
Testing boost pressure ...454
Testing exhaust gas temperature ...456
Testing exhaust gas color ...457
Testing and adjusting valve clearance ...459
Testing compression pressure ...461
Testing blowby pressure ...465
Testing engine oil pressure ...466
Testing EGR valve and KVGT oil pressures ...467
Testing fuel pressure ...468
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
Replacing alternator belt ...486
Power train ...487
Testing oil leakage from axle final drive ...487
Testing drive shaft for looseness, backlash, and damage ...488
Testing accelerator pedal ...489
Testing and adjusting HST oil pressure ...490
Testing transfer clutch control pressure ...493
Steering system ...494
Testing directional lever ...494
Testing steering wheel ...495
Testing work equipment control lever ...497
Testing and adjusting steering circuit oil pressure ...499
Bleeding air from steering cylinder circuit ...501
Brake system ...502
Testing brake pedal ...502
Testing braking performance ...503
Testing and adjusting of accumulator charge pressure ...504
Testing wheel brake oil pressure ...506
Testing lowering of wheel brake pressure ...507
Testing wear of wheel brake disc ...509
Bleeding air from wheel brake circuit ...510
Releasing remaining pressure in brake accumulator circuit ...511
Testing parking brake performance ...512
Testing wear of parking brake disc ...513
Testing parking brake release pressure ...514
Method of releasing parking brake manually ...515
Hydraulic system ...516
Testing cooling fan speed ...516
Testing cooling fan pump circuit oil pressure ...517
Bleeding air from hydraulic fan circuit ...519
Testing and adjusting work equipment PPC oil pressure ...520
Testing and adjusting work equipment oil pressure ...522
Bleeding air from work equipment circuit ...526
Releasing remaining pressure from work equipment circuit ...527
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ...529
Work equipment ...533
Testing and adjusting bucket positioner and bucket proximity switch ...533
Testing and adjusting boom position detection lever ...535
Electrical system ...536
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...536
Special functions of machine monitor ...537
Adjusting rearview camera angle ...615
Handling voltage circuit of engine controller ...616
Handling battery disconnect switch ...617
Testing diodes ...618
Pm clinic ...619
Pm Clinic service ...619
Check sheet ...620
40 Troubleshooting ...625
Table of contents ...626
Related information on troubleshooting ...635
Troubleshooting points ...635
Sequence of events in troubleshooting ...637
Checks before troubleshooting ...639
Inspection procedure before troubleshooting ...641
Preparation for troubleshooting of electrical system ...658
Classification and procedures for troubleshooting ...664
Symptom and troubleshooting numbers ...667
Information described in troubleshooting table ...670
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ...672
Connector list and layout ...675
Connector contact identification ...689
T-branch box and T-branch adapter table ...728
Fuse location table ...733
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ...736
Precautions when performing troubleshooting of machine monitor ...739
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ...741
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ...746
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ...747
Failure codes table ...748
Troubleshooting by failure code (Display of code) ...760
Failure code [2F00MA] Failure of Parking Brake Circuit ...760
Failure code [2F00MB] Malfunction of Parking Brake ...763
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...765
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ...767
Failure code [6091NX] HST Oil Filter Clogging ...769
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ...771
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. ...773
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ...775
Failure code [879AKA] A/C Inner Sensor Open Circuit ...777
Failure code [879AKB] A/C Inner Sensor Short Circuit ...778
Failure code [879BKA] A/C Outer Sensor Open Circuit ...779
Failure code [879BKB] A/C Outer Sensor Short Circuit ...780
Failure code [879CKA] Ventilating Sensor Open Circuit ...781
Failure code [879CKB] Ventilating Sensor Short Circuit ...782
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...783
Failure code [879EMC] Ventilation Damper Abnormality ...784
Failure code [879FMC] Air Mix Damper Abnormality ...785
Failure code [989L00] Engine Controller Lock Caution 1 ...786
Failure code [989M00] Engine Controller Lock Caution 2 ...787
Failure code [989N00] Engine Controller Lock Caution 3 ...788
Failure code [A1U0N3] HC Desorb Request 1 ...789
Failure code [A1U0N4] HC Desorb Request 2 ...791
Failure code [AB00KE] Charge Voltage Low ...793
Failure code [AB00KY] Hot Short of Alternator R Terminal ...794
Failure code [B@BAZG] Eng Oil Press Low ...795
Failure code [B@BCNS] Eng Water Overheat ...796
Failure code [B@BCZK] Eng Water Level Low ...797
Failure code [B@CRNS] HST Oil Temp. Overheat ...799
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ...800
Failure code [CA122] Chg Air Press Sensor High Error ...801
Failure code [CA123] Chg Air Press Sensor Low Error ...803
Failure code [CA131] Throttle Sensor High Error ...805
Failure code [CA132] Throttle Sensor Low Error ...807
Failure code [CA144] Coolant Temp Sens High Error ...809
Failure code [CA145] Coolant Temp Sens Low Error ...811
Failure code [CA153] Chg Air Temp Sensor High Error ...813
Failure code [CA154] Chg Air Temp Sensor Low Error ...815
Failure code [CA187] Sensor 2 Supply Volt Low Error ...817
Failure code [CA221] Ambient Press Sensor High Error ...819
Failure code [CA222] Ambient Press Sensor Low Error ...821
Failure code [CA227] Sensor 2 Supply Volt High Error ...823
Failure code [CA234] Eng Overspeed ...824
Failure code [CA238] Ne Speed Sensor Supply Volt Error ...825
Failure code [CA239] Ne Speed Sens Supply Volt High Error ...826
Failure code [CA271] IMV/PCV1 Short Error ...827
Failure code [CA272] IMV/PCV1 Open Error ...829
Failure code [CA295] Ambient Press Sens In Range Error ...831
Failure code [CA322] Inj #1(L#1) Open/Short Error ...832
Failure code [CA323] Inj #5(L#5) Open/Short Error ...834
Failure code [CA324] Inj #3(L#3) Open/Short Error ...836
Failure code [CA325] Inj #6(L#6) Open/Short Error ...838
Failure code [CA331] Inj #2(L#2) Open/Short Error ...840
Failure code [CA332] Inj #4(L#4) Open/Short Error ...842
Failure code [CA343] ECM Critical Internal Failure ...844
Failure code [CA351] Injectors Drive Circuit Error ...845
Failure code [CA352] Sensor 1 Supply Volt Low Error ...846
Failure code [CA356] Mass Air Flow Sensor High Error ...848
Failure code [CA357] Mass Air Flow Sensor Low Error ...850
Failure code [CA386] Sensor 1 Supply Volt High Error ...852
Failure code [CA428] Water in Fuel Sensor High Error ...853
Failure code [CA429] Water in Fuel Sensor Low Error ...855
Failure code [CA431] Idle Validation Sw Error ...857
Failure code [CA432] Idle Validation Process Error ...860
Failure code [CA435] Eng Oil Press Sw Error ...863
Failure code [CA441] Battery Voltage Low Error ...864
Failure code [CA442] Battery Voltage High Error ...866
Failure code [CA449] Rail Press Very High Error ...867
Failure code [CA451] Rail Press Sensor High Error ...868
Failure code [CA452] Rail Press Sensor Low Error ...870
Failure code [CA488] Chg Air Temp High Torque Derate ...872
Failure code [CA515] Rail Press Sens Sup Volt High Error ...873
Failure code [CA516] Rail Press Sens Sup Volt Low Error ...875
Failure code [CA553] Rail Press High Error ...877
Failure code [CA555] Crankcase Press High Error 1 ...878
Failure code [CA556] Crankcase Press High Error 2 ...879
Failure code [CA559] Rail Press Low Error ...880
Failure code [CA595] Turbo Speed High Error 2 ...882
Failure code [CA687] Turbo Speed Low Error ...883
Failure code [CA689] Eng Ne Speed Sensor Error ...885
Failure code [CA691] Intake Air Temp Sens High Error ...887
Failure code [CA692] Intake Air Temp Sens Low Error ...889
Failure code [CA697] ECM Internal Temp Sensor High Error ...891
Failure code [CA698] ECM Int Temp Sensor Low Error ...892
Failure code [CA731] Eng Bkup Speed Sens Phase Error ...893
Failure code [CA778] Eng Bkup Speed Sensor Error ...895
Failure code [CA1117] Persistent Data Lost Error ...900
Failure code [CA1664] KDOC Malfunction ...901
Failure code [CA1691] Regeneration Ineffective ...904
Failure code [CA1695] Sensor 5 Supply Volt High Error ...907
Failure code [CA1696] Sensor 5 Supply Volt Low Error ...908
Failure code [CA1843] Crankcase Press Sens High Error ...910
Failure code [CA1844] Crankcase Press Sens Low Error ...912
Failure code [CA1879] KDPF Delta P Sensor High Error ...914
Failure code [CA1881] KDPF Delta P Sensor Low Error ...916
Failure code [CA1883] KDPF Delta P Sens In Range Error ...918
Failure code [CA1921] KDPF Soot Load High Error 1 ...922
Failure code [CA1922] KDPF Soot Load High Error 2 ...925
Failure code [CA1942] Crankcase Press Sens In Range Error ...930
Failure code [CA1993] KDPF Delta Pressure Low Error ...931
Failure code [CA2185] Throt Sensor Sup Volt High Error ...934
Failure code [CA2186] Throt Sensor Sup Volt Low Error ...936
Failure code [CA2249] Rail Press Very Low Error ...938
Failure code [CA2271] EGR Valve Pos Sens High Error ...939
Failure code [CA2272] EGR Valve Pos Sens Low Error ...941
Failure code [CA2288] Turbo Speed High Error 1 ...944
Failure code [CA2311] IMV Solenoid Error ...945
Failure code [CA2349] EGR Valve Solenoid Open Error ...946
Failure code [CA2353] EGR Valve Solenoid Short Error ...948
Failure code [CA2357] EGR Valve Servo Error ...950
Failure code [CA2373] Exhaust Manifold Press Sens High error ...951
Failure code [CA2374] Exhaust Manifold Press Sens Low error ...953
Failure code [CA2375] EGR Orifice Temp Sens High Error ...955
Failure code [CA2376] EGR Orifice Temp Sens Low Error ...957
Failure code [CA2381] KVGT Pos Sens High Error ...959
Failure code [CA2382] KVGT Pos Sens Low Error ...961
Failure code [CA2383] KVGT Solenoid Open Error ...964
Failure code [CA2386] KVGT Solenoid Short Error ...966
Failure code [CA2387] KVGT Servo Error ...968
Failure code [CA2554] Exh Manifold Press Sens In Range Error ...969
Failure code [CA2555] Grid Htr Relay Volt Low Error ...970
Failure code [CA2556] Grid Htr Relay Volt High Error ...972
Failure code [CA2637] KDOC Face Plugging ...974
Failure code [CA2639] Manual Stationary Regeneration Request ...976
Failure code [CA2961] EGR Orifice Temp High Error 1 ...979
Failure code [CA2973] Chg Air Press Sensor In Range Error ...980
Failure code [CA3133] KDPF Outlet Press Sens High Error ...981
Failure code [CA3134] KDPF Outlet Press Sens Low Error ...983
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ...985
Failure code [CA3251] KDOC Inlet Temp High Error ...989
Failure code [CA3253] KDOC Temp Error - Non Regeneration ...992
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...995
Failure code [CA3255] KDPF Temp Error - Non Regeneration ...998
Failure code [CA3256] KDPF Outlet Temp High Error 1 ...1001
Failure code [CA3311] KDOC Outlet Temp High Error 2 ...1004
Failure code [CA3312] KDPF Outlet Temp High Error 2 ...1007
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...1010
Failure code [CA3314] KDOC Inlet Temp Sens High Error ...1013
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ...1016
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...1020
Failure code [CA3317] KDOC Outlet Temp Sens High Error ...1023
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...1026
Failure code [CA3319] KDPF Outlet Temp Sens High Error ...1030
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...1033
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...1036
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...1040
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...1042
Failure code [CA3741] Rail Press Valve Trip Error ...1044
Failure code [D110L4] Disconnection of Battery Relay Signal ...1045
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ...1047
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ...1049
Failure code [D191KA] Disconnection of Neutral Output Relay ...1051
Failure code [D191KB] Ground Fault of Neutral Output Relay ...1053
Failure code [D191KY] Hot Short of Neutral Output Relay ...1055
Failure code [D192KA] Disconnection of ECSS Solenoid ...1057
Failure code [D192KB] Ground Fault of ECSS Solenoid ...1059
Failure code [D192KY] Hot Short of ECSS Solenoid ...1060
Failure code [D19JKZ] Personal Code Relay Abnormality ...1061
Failure code [D1B0KA] Disconnection of HST Safety Relay ...1063
Failure code [D1B0KB] Ground Fault of HST Safety Relay ...1065
Failure code [D1B0KY] Hot Short of HST Safety Relay ...1067
Failure code [D1B0MC] Malfunction of HST Safety Relay ...1069
Failure code [D1E6KA] Disconnection of Parking Brake Relay ...1070
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ...1072
Failure code [D1E6KY] Hot Short of Parking Brake Relay ...1074
Failure code [D5ZHKA] Failure of Key SW C Signal ...1076
Failure code [D5ZHKB] Key SW C Signal Short Circuit ...1078
Failure code [D5ZHL6] Disconnection of Key SW C ...1080
Failure code [D811MC] KOMTRAX Error ...1081
Failure code [D862KA] GPS Antenna Open Circuit ...1082
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...1083
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...1085
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...1087
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ...1088
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...1090
Failure code [DAF0MB] Monitor ROM Abnormality ...1091
Failure code [DAF0MC] Monitor Error ...1092
Failure code [DAF3KK] Controller Power Source Low (MON) ...1093
Failure code [DAF8KB] Camera Power Supply Short Circuit ...1095
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ...1096
Failure code [DAFGMC] GPS Module Error ...1097
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ...1098
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ...1100
Failure code [DAFQKR] CAN2 Discon (Monitor) ...1102
Failure code [DAJ0KK] Controller Power Source Low (HST) ...1103
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ...1106
Failure code [DAJ0MC] HST Con Error ...1107
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ...1108
Failure code [DAJ2KK] Solenoid Power Source Low (HST) ...1110
Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ...1113
Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay ...1115
Failure code [DAJ5KX] Failure of 5V Power Source 0 ...1117
Failure code [DAJ6KX] Failure of 5V Power Source 1 ...1119
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) ...1121
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ...1122
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) ...1124
Failure code [DAJQKR] CAN2 Discon ( HST Con) ...1126
Failure code [DAJRKR] CAN1 Discon ( HST Con) ...1127
Failure code [DAJRMA] Inconsistency of Option Selection (HST) ...1128
Failure code [DAZ9KQ] A/C Model Selection Abnormality ...1129
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...1130
Failure code [DB2QKR] CAN2 Discon (Engine Con) ...1131
Failure code [DB2RKR] CAN1 Discon (Engine Con) ...1136
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...1140
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ...1142
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ...1144
Failure code [DDB6L4] Parking Brake Signal Malfunction ...1146
Failure code [DDD7KA] Failure of Variable Speed Control ...1149
Failure code [DDD7KY] Hot Short of Variable Speed Control ...1151
Failure code [DDK3KA] FNR SW Input Signal Disconnection ...1153
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ...1155
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...1157
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...1160
Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ...1162
Failure code [DF10KA] Disconnection of Speed Range Input ...1164
Failure code [DF10KB] Ground Fault of Speed Range Input ...1167
Failure code [DGH1KX] Out of Range of HST Oil Temp. Sensor ...1170
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ...1172
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ...1174
Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ...1176
Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) ...1178
Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ...1180
Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) ...1182
Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) ...1184
Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ...1186
Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ...1188
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. ...1190
Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ...1192
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ...1194
Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ...1196
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ...1198
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ...1200
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit ...1202
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ...1204
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit ...1206
Failure code [DHT8ZG] Steering Oil Pressure Low ...1208
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ...1209
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ...1211
Failure code [DK55KA] Failure of FNR Lever Potentio ...1213
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...1216
Failure code [DK55L5] Failure of FNR Lever Potentio ...1218
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...1219
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ...1222
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...1225
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ...1228
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ...1231
Failure code [DK70KA] Failure of inching sensor Circuit ...1234
Failure code [DK70KY] Hot Short of inching sensor Circuit ...1237
Failure code [DKA0KA] Failure of Boom Angle Sensor ...1239
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ...1241
Failure code [DKA0L0] Boom Angle Sensor Dislocation ...1243
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ...1245
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...1247
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ...1248
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ...1250
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ...1252
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ...1255
Failure code [DPQ1KR] LIN Discon (Switch Panel) ...1257
Failure code [DPQ2KR] LIN Discon (LED Unit) ...1260
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ...1263
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...1266
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...1268
Failure code [DV00KB] Ground Fault of Buzzer Output ...1270
Failure code [DW26KA] Disconnection of Motor 2 Solenoid ...1272
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ...1274
Failure code [DW26KY] Hot Short of Motor 2 Solenoid ...1276
Failure code [DW4BKA] Disconnection of Parking Brake Valve ...1278
Failure code [DW4BKB] Ground Fault of Parking Brake Valve ...1280
Failure code [DW4BKY] Hot Short of Parking Brake Valve ...1282
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...1283
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ...1285
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...1287
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ...1288
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ...1290
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ...1292
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...1293
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ...1295
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ...1297
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ...1299
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...1301
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ...1303
Failure code [DX19KA] Disconnection of Motor 1 Solenoid ...1304
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ...1306
Failure code [DX19KY] Hot Short of Motor 1 Solenoid ...1308
Failure code [DX20KA] Disconnection of Clutch Control Solenoid ...1310
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ...1312
Failure code [DX20KY] Hot Short of Clutch Control Solenoid ...1314
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. ...1316
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ...1318
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. ...1320
Failure code [DXH7KA] Disconnection of Reverse Solenoid ...1322
Failure code [DXH7KB] Ground Fault of Reverse Solenoid ...1324
Failure code [DXH7KY] Hot Short of Reverse Solenoid ...1326
Failure code [DXH8KA] Disconnection of Forward Solenoid ...1328
Failure code [DXH8KB] Ground Fault of Forward Solenoid ...1330
Failure code [DXH8KY] Hot Short of Forward Solenoid ...1332
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...1334
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ...1336
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ...1338
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...1339
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ...1341
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ...1343
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...1344
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ...1347
Failure code [J141N1] Steering Pump Over Run ...1349
Failure code [LA00L3] Failure of Fan Reverse ...1350
Failure code [M100N1] HST Pump Over Run ...1351
Failure code [M400N1] HST Motor 1 Over Run ...1352
Troubleshooting of electrical system (E-mode) ...1353
E-1 Engine does not start ...1353
E-2 Manual preheating system does not work ...1360
E-3 Automatic preheating system does not work ...1363
E-4 While preheating is working, preheating monitor does not light up ...1365
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ...1367
E-6 LCD unit on machine monitor displays nothing ...1370
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ...1372
E-8 LCD on machine monitor does not display properly ...1374
E-9 Meter unit display on machine monitor is abnormal ...1376
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...1379
E-11 Caution LED on machine monitor is abnormal ...1382
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...1384
E-13 Two switches operation of switch panel on machine monitor does not function ...1386
E-14 Switch panel buzzer of machine monitor is abnormal ...1389
E-15 Rearview monitor does not light up or backlight flickers ...1391
E-16 Rearview monitor images are not displayed clearly ...1394
E-17 Rearview monitor brightness cannot be adjusted ...1397
E-18 Night lighting lamp of rearview monitor is abnormal ...1400
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ...1402
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ...1403
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ...1407
E-22 The HST oil filter clogging caution lamp does not light up ...1409
E-23 Radiator coolant level caution lamp does not light ...1411
E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light ...1413
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 ...1414
E-26 Fuel level gauge does not indicate correct level ...1416
E-27 Seat belt caution lamp indication is abnormal ...1418
E-28 Horn does not sound ...1419
E-29 Horn does not stop sounding ...1422
E-30 Alarm buzzer does not sound ...1424
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ...1426
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 ...1427
E-33 Setting does not change while operating traction control switch ...1429
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 ...1431
E-35 Remote positioner does not work or cannot be released ...1434
E-36 Bucket positioner does not work or cannot be released ...1436
E-37 Direction selector (FNR) switch mode is not selected or not released ...1439
E-38 PZ auto tilt-in does not work ...1441
E-39 Tracktion level does not display MAX when max traction switch is turned ON ...1444
E-40 ECSS function cannot be selected or cannot be released ...1446
E-41 None of headlamp, clearance lamp, and tail lamp lights ...1448
E-42 Clearance lamp, tail lamp and license-plate lamp do not light up or go out ...1450
E-43 Both High and Low beams of headlamp do not light up or go out ...1454
E-44 Low beam of headlamp does not light up or go out ...1458
E-45 High beam of headlamp does not light up or go out ...1460
E-46 Front working lamp does not light up or go out ...1462
E-47 Rear working lamp does not light up or go out ...1466
E-48 All of turn signal lamps and hazard lamps do not flash or go out ...1470
E-49 Turn signal lamps do not flash or go out ...1473
E-50 Hazard lamp does not flash or go out ...1476
E-51 Brake lamp does not light or stays lighted ...1479
E-52 Backup lamp does not light up or does not go out ...1482
E-53 Backup buzzer does not sound or continues to sound ...1485
E-54 Front wiper does not operate ...1487
E-55 Rear wiper does not operate ...1490
E-56 Window washer does not operate ...1492
E-57 KOMTRAX system does not operate normally ...1495
Troubleshooting of hydraulic and mechanical system (H-mode) ...1497
Information described in troubleshooting table (H-mode) ...1497
System chart of hydraulic and mechanical systems ...1498
Failure mode and cause table ...1500
H-1 Machine does not travel forward or backward ...1506
H-2 Machine does not travel forward (Machine travels backward normally) ...1509
H-3 Machine does not travel backward (Machine travels forward normally) ...1510
H-4 Machine does not travel forward or backward fast ...1511
H-5 Machine does not travel forward fast (Machine travel backward fast) ...1515
H-6 Machine does not travel backward fast (Machine travel forward fast) ...1516
H-7 Machine lacks power neither when traveling forward nor backward ...1517
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ...1520
H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ...1521
H-10 Engine stalls during travel or engine speed drops significantly ...1522
H-11 Steering wheel is too heavy to turn ...1523
H-12 Steering wheel is heavy to turn ...1525
H-13 Machine sways or large shocks are made while machine turns ...1526
H-14 Machine unintentionally turns when machine travels ...1527
H-15 Wheel brakes do not work or are weak ...1528
H-16 Wheel brakes are not released or drag ...1529
H-17 Parking brake does not work or it is weak ...1530
H-18 Parking brake is not released or drags. ...1531
H-19 Boom does not rise ...1532
H-20 Boom moves slow or boom lacks lifting force ...1534
H-21 Rising boom slows down at certain height ...1536
H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground). ...1537
H-23 Hydraulic drift of boom is large ...1538
H-24 Boom moves up and down during operation ...1539
H-25 Bucket does not tilt back ...1540
H-26 Bucket moves slow or lacks tilt-back force ...1542
H-27 Bucket decelerates during tilt-back operation ...1544
H-28 Bucket cylinder does not hold bucket on ground ...1545
H-29 Hydraulic drift of bucket is large ...1546
H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ...1547
H-31 Boom and bucket control levers do not move smoothly and are heavy to move ...1548
H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ...1549
H-33 Large shocks are made when work equipment starts to move and stops ...1550
H-34 When certain work equipment is relieved hydraulically, other work equipment moves ...1551
H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ...1552
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) ...1553
H-37 Unusual noise is heard from around fan ...1555
Troubleshooting of engine (S-mode) ...1556
Information described in troubleshooting table (S mode) ...1556
S-1 Engine does not crank when starting switch is turned to START position ...1557
S-2 Engine cranks but no exhaust smoke comes out ...1558
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ...1559
S-4 Engine startability is poor ...1560
S-5 Engine does not pick up smoothly ...1562
S-6 Engine stops during operation ...1564
S-7 Engine runs rough or is unstable ...1566
S-8 Engine lacks power ...1567
S-9 KDPF gets clogged in a short time ...1569
S-10 Engine oil consumption is excessive ...1571
S-11 Engine oil becomes contaminated early ...1572
S-12 Fuel consumption is excessive ...1573
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...1574
S-14 Oil pressure drops ...1575
S-15 Fuel mixes into engine oil ...1576
S-16 Water mixes into engine oil (milky) ...1577
S-17 Coolant temperature rises too high (overheating) ...1578
S-18 Unusual noise is heard ...1579
S-19 Vibration is excessive ...1580
S-20 Air cannot be bled from fuel circuit ...1582
S-21 Active regeneration is executed frequently ...1583
S-22 Active regeneration takes time ...1584
S-23 White smoke is exhausted during active regeneration ...1585
50 Disassembly and assembly ...1587
Table of contents ...1588
Related information on disassembly and assembly ...1590
How to read this manual ...1590
Coating materials list ...1592
Special tools list ...1596
Sketches of special tools ...1603
Engine and cooling system ...1619
Removal and installation of supply pump assembly ...1619
Removal and installation of injector assembly ...1623
Removal and installation of cylinder head assembly ...1632
Removal and installation of engine hood assembly ...1639
Removal and installation of grille assembly ...1642
Removal and installation of radiator core assembly ...1644
Removal and installation of aftercooler ...1647
Removal and installation of hydraulic oil cooler ...1649
Removal and installation of engine assembly ...1650
Removal and installation of engine front oil seal ...1656
Removal and installation of engine rear oil seal ...1659
Removal and installation of cooling fan and fan motor assembly ...1662
Removal and installation of KDPF assembly ...1664
Disassembly and assembly of KDPF assembly ...1668
Removal and installation of KCCV assembly ...1677
Removal and installation of air cleaner assembly ...1678
Removal and installation of KVGT assembly ...1680
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ...1684
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ...1686
Removal and installation of alternator belt ...1689
Removal and installation of fuel tank assembly ...1691
Power train ...1694
Removal and installation of transfer assembly ...1694
Disassembly and assembly of transfer assembly ...1699
Disassembly and assembly of parking brake assembly ...1731
Disassembly and assembly of differential assembly ...1739
Removal and installation of front axle assembly ...1763
Removal and installation of rear axle assembly ...1765
Disassembly and assembly of axle housing assembly ...1768
Undercarriage and frame ...1777
Removal and installation of center hinge pin ...1777
Removal and installation of counterweight assembly ...1786
Hydraulic system ...1788
Removal and installation of hydraulic tank assembly ...1788
Removal and installation of control valve assembly ...1791
Disassembly and assembly of control valve assembly ...1795
Removal and installation of hydraulic pump assembly ...1798
Removal and installation of HST motor1 assembly ...1802
Removal and installation of HST motor2 assembly ...1804
Disassembly and assembly of hydraulic cylinder assembly ...1806
Work equipment ...1813
Removal and installation of work equipment assembly ...1813
Cab and its attachments ...1819
Removal and installation of operator's cab and floor frame assembly ...1819
Removal and installation of operator's cab glass (adhered glass) ...1824
Removal and installation of operator's seat assembly ...1832
Removal and installation of seat belt ...1834
Electrical system ...1835
Removal and installation of machine monitor assembly ...1835
Removal and installation of engine controller assembly ...1837
Removal and installation of HST controller assembly ...1839
Removal and installation of air conditioner controller assembly ...1841
Removal and installation of monitor controller assembly ...1842
Removal and installation of mass air flow and temperature sensor ...1844
Removal and installation of KOMTRAX terminal assembly ...1845
Air conditioner unit ...1846
Removal and installation of air conditioner compressor ...1846
Removal and installation of air conditioner condenser ...1848
Removal and installation of air conditioner unit assembly ...1850
60 Maintenance standard ...1855
Table of contents ...1856
Engine and cooling system ...1857
Engine related parts ...1857
Cooling fan motor ...1858
Power train ...1860
Damper ...1860
Transfer ...1861
Drive shaft ...1868
Axle ...1869
Differential ...1871
Limited slip differential ...1875
Final drive ...1877
Steering system ...1881
Steering column ...1881
Priority valve ...1882
Emergency steering valve ...1883
Steering cylinder ...1884
Brake system ...1886
Brake accumulator charge valve ...1886
Slack adjuster ...1887
Brake ...1888
Parking brake ...1890
Parking brake solenoid valve ...1891
Undercarriage and frame ...1892
Axle mount ...1892
Center hinge pin ...1894
Hydraulic system ...1898
Hydraulic tank ...1898
Double type gear pump ...1899
Steering and work equipment pump ...1900
Control valve ...1904
Self-pressure reducing valve ...1917
Work equipment PPC valve ...1919
Work equipment lock solenoid valve ...1921
Work equipment ...1922
Work equipment linkage ...1922
Bucket ...1926
Work equipment cylinder ...1928
Cab and its attachments ...1929
Cab mount ...1929
Electrical system ...1930
Bucket positioner ...1930
Fork positioner ...1931
Remote boom positioner ...1932
80 Appendix ...1933
Table of contents ...1934
Air conditioner components ...1935
Precautions for refrigerant ...1935
Air conditioner component ...1936
Configuration and function of refrigeration cycle ...1938
Outline of refrigeration cycle ...1939
Air conditioner unit ...1941
Dual pressure switch ...1946
Air conditioner controller ...1947
Compressor ...1948
Condenser ...1949
Receiver drier ...1950
Sunlight sensor ...1952
Outer temperature sensor (outside air temperature sensor) ...1953
Procedure for testing and troubleshooting ...1954
Circuit diagram and arrangement of connector pins ...1956
System diagram ...1959
Parts and connectors layout ...1962
Testing with self-diagnosis function ...1967
How to open the electrical system abnormality record screen in service mode of the machine monitor ...1968
Testing temperature control system ...1970
Testing vent (mode) changeover ...1972
Testing FRESH/RECIRC air changeover ...1974
Testing evaporator temperature sensor ...1976
Testing relays ...1978
Troubleshooting chart 1 ...1980
Troubleshooting chart 2 ...1981
Information in troubleshooting table ...1983
Failure code list related to air conditioner ...1984
Failure code [879AKA] A/C Inner Sensor Open Circuit ...1985
Failure code [879AKB] A/C Inner Sensor Short Circuit ...1987
Failure code [879BKA] A/C Outer Sensor Open Circuit ...1989
Failure code [879BKB] A/C Outer Sensor Short Circuit ...1991
Failure code [879CKA] Ventilating Sensor Open Circuit ...1993
Failure code [879CKB] Ventilating Sensor Short Circuit ...1995
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...1997
Failure code [879EMC] Ventilation Damper Abnormality ...1999
Failure code [879FMC] Air Mix Damper Abnormality ...2002
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ...2005
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...2008
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...2011
A-4 Troubleshooting for FRESH/RECIRC air changeover ...2014
Troubleshooting with gauge pressure ...2016
Connection of service tool ...2019
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ...2021
Handling of compressor oil ...2023
90 Diagrams and drawings ...2025
Table of contents ...2026
Hydraulic circuit diagram ...2027
Symbols in hydraulic circuit diagram ...2027
Hydraulic circuit diagram ...2031
Electric circuit diagram ...2032
Symbols in electric circuit diagram ...2032
Electrical circuit diagram of machine body ...2036
Electrical circuit diagram of floor ...2040
INDEX...2048
CEBM031301 - Wheel Loader WA270-8 Shop Manual...2060
Shop Manual, WA270-8...0
00 INDEX AND FOREWORD...2062
INDEX...2063
ABBREVIATION LIST...2082
FOREWORD, SAFETY, BASIC INFORMATION...2087
HOW TO READ THE SHOP MANUAL...2087
SAFETY NOTICE FOR OPERATION...2089
PRECAUTIONS TO PREVENT FIRE...2097
ACTIONS IF FIRE OCCURS...2099
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...2100
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...2101
PRECAUTIONS FOR DEF...2102
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...2102
PRECAUTIONS FOR ADDING...2102
PRECAUTIONS FOR STORING...2102
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...2102
THE OTHER PRECAUTIONS...2102
STORE AdBlue/DEF...2103
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...2104
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...2107
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...2113
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...2115
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...2116
PRACTICAL USE OF KOMTRAX...2117
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...2118
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...2118
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...2119
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...2120
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...2122
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...2126
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...2127
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...2129
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...2130
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...2132
HOW TO READ ELECTRICAL WIRE CODE...2133
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...2137
STANDARD TIGHTENING TORQUE TABLE...2140
CONVERSION TABLE...2147
01 SPECIFICATIONS...2152
CONTENTS...2153
ABBREVIATION LIST...2154
SPECIFICATIONS...2159
SPECIFICATION DRAWING...2159
SPECIFICATION DRAWING: WA270-8...2159
SPECIFICATIONS...2161
SPECIFICATIONS: WA270-8...2161
WEIGHT TABLE...2166
WEIGHT TABLE: WA270-8...2166
TABLE OF FUEL, COOLANT, AND LUBRICANTS...2168
10 STRUCTURE AND FUNCTION...2170
CONTENTS...2171
ABBREVIATION LIST...2175
UREA SCR SYSTEM...2180
LAYOUT DRAWING OF UREA SCR SYSTEM...2180
UREA SCR SYSTEM DIAGRAM...2182
FUNCTION OF UREA SCR SYSTEM...2183
FUNCTION OF AdBlue/DEF SYSTEM...2183
INDUCEMENT STRATEGY...2186
COMPONENT PARTS OF UREA SCR SYSTEM...2201
AdBlue/DEF MIXING TUBE...2201
SCR ASSEMBLY...2202
AdBlue/DEF TANK...2204
AdBlue/DEF PUMP...2206
AdBlue/DEF INJECTOR...2207
AdBlue/DEF HOSE...2208
AdBlue/DEF TANK HEATING VALVE...2209
BOOT-UP SYSTEM...2210
LAYOUT DRAWING OF BOOT-UP SYSTEM...2210
SYSTEM OPERATING LAMP SYSTEM...2212
SYSTEM OPERATING LAMP SYSTEM DIAGRAM...2212
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...2212
BATTERY DISCONNECT SWITCH...2213
FUNCTION OF BATTERY DISCONNECT SWITCH...2213
PREHEATING SYSTEM...2214
PREHEATING SYSTEM DIAGRAM...2214
FUNCTION OF AUTOMATIC PREHEATING SYSTEM...2214
OPERATION OF AUTOMATIC PREHEATING SYSTEM...2214
FUNCTION OF MANUAL PREHEATING SYSTEM...2215
OPERATION OF MANUAL PREHEATING SYSTEM...2215
ENGINE SYSTEM...2216
LAYOUT DRAWING OF ENGINE SYSTEM...2216
FUNCTION OF ENGINE SYSTEM...2217
ENGINE CONTROL SYSTEM...2218
ENGINE CONTROL SYSTEM DIAGRAM...2218
FUNCTION OF ENGINE CONTROL SYSTEM...2220
OPERATION OF ENGINE CONTROL SYSTEM...2223
AUTOMATIC IDLE STOP SYSTEM...2225
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...2225
COMPONENT PARTS OF ENGINE SYSTEM...2226
DAMPER...2226
VGT...2227
EGR SYSTEM...2231
EGR VALVE...2233
EGR COOLER...2235
KCCV SYSTEM...2237
KCCV VENTILATOR...2239
KDPF...2241
COOLING SYSTEM...2245
LAYOUT DRAWING OF COOLING SYSTEM...2245
SPECIFICATIONS OF COOLING SYSTEM...2246
COOLING FAN CONTROL SYSTEM...2247
COOLING FAN CONTROL SYSTEM DIAGRAM...2247
FUNCTION OF COOLING FAN CONTROL SYSTEM...2247
COMPONENT PARTS OF COOLING SYSTEM...2252
COOLING FAN MOTOR...2252
CONTROL SYSTEM...2265
LAYOUT DRAWING OF CONTROL SYSTEM...2265
MACHINE MONITOR SYSTEM...2267
MACHINE MONITOR SYSTEM DIAGRAM...2267
FUNCTION OF MACHINE MONITOR SYSTEM...2267
REARVIEW MONITOR SYSTEM...2269
REARVIEW MONITOR SYSTEM DIAGRAM...2269
FUNCTION OF REARVIEW MONITOR SYSTEM...2269
KOMTRAX SYSTEM...2270
KOMTRAX SYSTEM DIAGRAM...2270
FUNCTION OF KOMTRAX SYSTEM...2270
COMPONENT PARTS OF CONTROL SYSTEM...2271
MACHINE MONITOR...2271
SWITCH PANEL...2288
REARVIEW MONITOR...2289
REARVIEW CAMERA...2291
KOMTRAX TERMINAL...2292
MONITOR CONTROLLER...2294
HST CONTROLLER...2299
CAN TERMINATING RESISTOR...2303
ENGINE CONTROLLER...2304
ACCELERATOR PEDAL...2311
HYDRAULIC SYSTEM...2313
LAYOUT DRAWING OF HYDRAULIC SYSTEM...2313
CLSS...2314
STRUCTURE OF CLSS...2314
FUNCTION OF CLSS...2315
COMPONENT PARTS OF HYDRAULIC SYSTEM...2317
HYDRAULIC TANK...2317
HYDRAULIC OIL FILTER...2320
STEERING AND WORK EQUIPMENT PUMP...2321
BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP...2334
CONTROL VALVE...2335
POWER TRAIN SYSTEM...2365
LAYOUT DRAWING OF POWER TRAIN SYSTEM...2365
OPERATION OF POWER TRAIN SYSTEM...2367
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION...2368
HST CONTROL SYSTEM...2370
HST CONTROL SYSTEM DIAGRAM...2370
ENGINE OVERRUN PREVENTION FUNCTION...2371
NEUTRALIZER FUNCTION...2371
HST CHARGE SYSTEM...2372
SYSTEM DIAGRAM OF HST CHARGE SYSTEM...2372
FUNCTION OF HST CHARGE SYSTEM...2372
HST PUMP CONTROL SYSTEM...2373
SYSTEM DIAGRAM OF HST PUMP CONTROL SYSTEM...2373
DIRECTIONAL SELECTION FUNCTION...2373
ABSORBING TORQUE CONTROL FUNCTION...2373
INCHING CONTROL FUNCTION...2374
TRAVEL SPEED ADJUSTMENT FUNCTION (AT LOW SPEED)...2374
HST CONTROLLER GEAR SHIFT CONTROL FUNCTION...2375
GEAR SHIFT FUNCTION...2375
GEAR SHIFT DISPLAY FUNCTION...2377
TRAVEL SPEED ADJUSTMENT FUNCTION...2377
TRANSFER CLUTCH CONTROL FUNCTION...2378
HST SYSTEM PROTECTION FUNCTION...2379
TRANSFER PROTECTION FUNCTION...2379
DIRECTION PROTECTION FUNCTION...2379
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 1...2379
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 2...2380
TRAVEL SPEED LIMITATION FUNCTION...2381
MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL...2382
FUNCTION OF MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL...2382
KOMATSU TRACTION CONTROL SYSTEM (KTCS)...2385
KOMATSU TRACTION CONTROL SYSTEM (KTCS) DIAGRAM...2385
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS)...2385
COMPONENT PARTS OF POWER TRAIN SYSTEM...2390
DRIVE SHAFT...2390
HST PUMP...2392
HST CHARGE PUMP...2404
HST MOTOR...2406
TRANSFER...2412
AXLE...2420
TORQUE PROPORTIONING DIFFERENTIAL...2422
LIMITED SLIP DIFFERENTIAL...2426
FINAL DRIVE...2430
COMBINATION SWITCH...2432
WORK EQUIPMENT SYSTEM...2436
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...2436
WORK EQUIPMENT CONTROL SYSTEM...2438
WORK EQUIPMENT LEVER OPERATION FUNCTION...2438
PZ AUTO TILT-IN COMPENSATION CONTROL FUNCTION...2438
WORK EQUIPMENT LOCK SYSTEM...2439
WORK EQUIPMENT LOCK SYSTEM DIAGRAM...2439
FUNCTION OF WORK EQUIPMENT LOCK SYSTEM...2439
BUCKET POSITIONER SYSTEM...2441
BUCKET POSITIONER SYSTEM DIAGRAM...2441
FUNCTION OF BUCKET POSITIONER SYSTEM...2441
OPERATION OF BUCKET POSITIONER SYSTEM...2443
FORK POSITIONER SYSTEM...2445
FORK POSITIONER SYSTEM DIAGRAM...2445
FUNCTION OF FORK POSITIONER SYSTEM...2445
OPERATION OF FORK POSITIONER SYSTEM...2446
REMOTE POSITIONER SYSTEM...2449
REMOTE BOOM POSITIONER SYSTEM DIAGRAM...2449
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM...2449
ECSS...2452
ECSS DIAGRAM...2452
FUNCTION OF ECSS...2452
OPERATION OF ECSS...2452
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...2454
SELF-PRESSURE REDUCING VALVE...2454
WORK EQUIPMENT LOCK SOLENOID VALVE...2459
PILOT CIRCUIT ACCUMULATOR...2460
ECSS CIRCUIT ACCUMULATOR...2461
MULTIFUNCTION MONO-LEVER...2462
MULTIFUNCTION MONO-LEVER PPC VALVE...2464
STEERING SYSTEM...2469
LAYOUT DRAWING OF STEERING SYSTEM...2469
STEERING COLUMN...2470
STRUCTURE OF STEERING COLUMN...2470
COMPONENT PARTS OF STEERING SYSTEM...2471
PRIORITY VALVE...2471
ORBITROL VALVE...2474
CUSHION VALVE...2479
2-WAY RESTRICTOR VALVE...2481
SECONDARY STEERING VALVE...2482
BRAKE SYSTEM...2485
LAYOUT DRAWING OF BRAKE SYSTEM...2485
PARKING BRAKE CONTROL SYSTEM...2487
PARKING BRAKE CONTROL SYSTEM DIAGRAM...2487
OPERATION OF PARKING BRAKE CONTROL SYSTEM...2487
COMPONENT PARTS OF BRAKE SYSTEM...2491
BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE...2491
PARKING BRAKE SOLENOID VALVE...2495
BRAKE CIRCUIT ACCUMULATOR...2497
BRAKE VALVE...2499
SLACK ADJUSTER...2502
BRAKE...2504
PARKING BRAKE...2507
AUTO-GREASING SYSTEM...2509
LAYOUT DRAWING OF AUTO-GREASING SYSTEM...2509
SPECIFICATIONS OF AUTO-GREASING SYSTEM...2510
FUNCTION OF AUTO-GREASING SYSTEM...2511
COMPONENT PARTS OF AUTO-GREASING SYSTEM...2512
AUTO-GREASING PUMP...2512
UNDERCARRIAGE AND FRAME...2513
FRAME, AXLE MOUNT AND CENTER HINGE PIN...2513
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...2513
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...2514
TIRE...2516
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE...2516
STRUCTURE OF RADIAL TIRE...2516
FUNCTION OF RADIAL TIRE...2516
STRUCTURE OF BIAS TIRE...2517
FUNCTION OF BIAS TIRE...2517
WORK EQUIPMENT...2518
STRUCTURE OF WORK EQUIPMENT...2518
STRUCTURE OF BUCKET...2519
CAB AND ITS ATTACHMENTS...2520
ROPS CAB...2520
STRUCTURE OF ROPS CAB...2520
FUNCTION OF ROPS CAB...2520
CAB MOUNT...2521
STRUCTURE OF CAB MOUNT...2521
FUNCTION OF CAB MOUNT...2521
20 STANDARD VALUE TABLE...2522
CONTENTS...2523
ABBREVIATION LIST...2524
STANDARD VALUE TABLE FOR ENGINE...2529
STANDARD VALUE TABLE FOR ENGINE: WA270-8...2529
STANDARD VALUE TABLE FOR MACHINE...2534
STANDARD VALUE TABLE FOR MACHINE: WA270-8...2534
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...2548
30 TESTING AND ADJUSTING...2552
CONTENTS...2553
ABBREVIATION LIST...2557
RELATED INFORMATION ON TESTING AND ADJUSTING...2562
TOOLS FOR TESTING AND ADJUSTING...2562
SKETCH OF TOOLS FOR TESTING AND ADJUSTING...2571
ENGINE AND COOLING SYSTEM...2572
TEST ENGINE SPEED...2572
METHOD FOR TESTING ENGINE SPEED...2572
TEST BOOST PRESSURE...2575
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR...2575
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL...2576
TESTING EXHAUST GAS TEMPERATURE...2578
METHOD FOR TESTING EXHAUST GAS TEMPERATURE...2578
TEST EXHAUST GAS COLOR...2580
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...2580
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...2582
TEST AND ADJUST VALVE CLEARANCE...2584
METHOD FOR TESTING VALVE CLEARANCE...2584
METHOD FOR ADJUSTING VALVE CLEARANCE...2585
TEST COMPRESSION PRESSURE...2586
METHOD FOR TESTING COMPRESSION PRESSURE...2586
TEST BLOWBY PRESSURE...2591
METHOD FOR TESTING BLOWBY PRESSURE...2591
TEST ENGINE OIL PRESSURE...2594
METHOD FOR TESTING ENGINE OIL PRESSURE...2594
TEST EGR VALVE AND VGT OIL PRESSURE...2596
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE...2596
TEST FUEL PRESSURE...2598
METHOD FOR TESTING FUEL PRESSURE...2599
TEST FUEL DISCHARGE, RETURN AND LEAKAGE...2604
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE...2605
BLEED AIR FROM FUEL SYSTEM...2611
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM...2611
TEST FUEL CIRCUIT FOR LEAKAGE...2613
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...2613
HANDLE CYLINDER CUT-OUT MODE OPERATION...2615
HANDLE NO-INJECTION CRANKING OPERATION...2616
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...2617
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...2617
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...2618
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...2618
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS...2619
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS...2619
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...2620
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT...2620
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT...2620
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...2622
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...2622
TEST SCR RELATED FUNCTIONS...2623
TEST AdBlue/DEF PUMP RAISED PRESSURE...2627
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR...2630
TEST AdBlue/DEF LINE HEATER RELAY 1...2635
TEST AdBlue/DEF LINE HEATER RELAY 2...2639
TEST AdBlue/DEF PUMP HEATER RELAY...2643
TEST AdBlue/DEF TANK HEATER VALVE...2647
TEST SCR NOx REMOVAL EFFICIENCY...2651
CLEAN AdBlue/DEF TANK...2655
METHOD FOR CLEANING AdBlue/DEF TANK...2655
POWER TRAIN...2659
TEST AND ADJUST HST OIL PRESSURE...2659
METHOD FOR TESTING HST OIL PRESSURE...2659
METHOD FOR ADJUSTING HST OIL PRESSURE...2661
TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH...2663
METHOD FOR TESTING THE CONTROL PRESSURE OF TRANSFER CLUTCH...2663
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...2665
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...2665
STEERING SYSTEM...2666
TEST STEERING WHEEL...2666
METHOD FOR TESTING STEERING WHEEL...2666
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE...2668
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE ON MACHINE MONITOR...2668
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE BY TESTING TOOL...2669
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE...2669
BLEED AIR FROM STEERING CYLINDER CIRCUIT...2671
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT...2671
BRAKE SYSTEM...2672
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...2672
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...2672
TEST WHEEL BRAKE OIL PRESSURE...2673
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE...2673
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE...2675
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE...2675
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE...2676
TEST BRAKING PERFORMANCE...2677
METHOD FOR TESTING BRAKING PERFORMANCE...2677
TEST BRAKE PEDAL...2678
METHOD FOR TESTING BRAKE PEDAL...2678
BLEED AIR FROM BRAKE CIRCUIT...2679
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT...2679
TEST LOWERING OF WHEEL BRAKE PRESSURE...2680
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE...2681
TEST WEAR OF WHEEL BRAKE DISC...2683
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC...2683
TEST PARKING BRAKE OIL PRESSURE...2685
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE...2685
TEST PARKING BRAKE PERFORMANCE...2687
METHOD FOR TESTING PARKING BRAKE PERFORMANCE...2687
RELEASE PARKING BRAKE MANUALLY...2688
METHOD FOR RELEASING PARKING BRAKE MANUALLY...2688
TEST WEAR AMOUNT OF PARKING BRAKE DISC...2689
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC...2689
HYDRAULIC SYSTEM...2690
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...2690
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...2690
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE...2692
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE...2692
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE...2696
TEST AND ADJUST WORK EQUIPMENT PPC OIL PRESSURE...2698
METHOD FOR TESTING WORK EQUIPMENT PPC OIL PRESSURE...2698
METHOD FOR ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...2700
BLEED AIR FROM WORK EQUIPMENT CIRCUIT...2702
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...2702
TEST COOLING FAN SPEED...2704
METHOD FOR TESTING COOLING FAN SPEED...2704
TEST COOLING FAN CIRCUIT OIL PRESSURE...2705
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE...2705
BLEED AIR FROM COOLING FAN CIRCUIT...2708
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT...2708
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS...2710
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE...2710
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS...2712
WORK EQUIPMENT...2716
TEST AND ADJUST BUCKET POSITIONER...2716
METHOD FOR TESTING BUCKET POSITIONER...2716
METHOD FOR ADJUSTING BUCKET POSITIONER...2716
TEST AND ADJUST BOOM POTENTIOMETER LEVER...2718
METHOD FOR TESTING BOOM POTENTIOMETER LEVER...2718
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER...2718
CAB AND ITS ATTACHMENTS...2719
TEST DIRECTIONAL LEVER...2719
METHOD FOR TESTING DIRECTIONAL LEVER...2719
TEST MULTIFUNCTION MONO-LEVER...2720
METHOD FOR TESTING MULTIFUNCTION MONO-LEVER...2720
TEST ACCELERATOR PEDAL...2722
METHOD FOR TESTING ACCELERATOR PEDAL...2722
ELECTRICAL SYSTEM...2724
SET AND ADJUST EACH EQUIPMENT...2724
SET AND OPERATE MACHINE MONITOR...2727
OPERATOR MODE...2731
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN...2731
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN...2731
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)...2732
CHECKING FUNCTION OF SERVICE METER AND ODOMETER...2733
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD...2733
SERVICE MODE...2737
METHOD FOR OPERATING SERVICE MODE...2737
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...2740
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...2747
ABNORMALITY RECORD MENU...2759
METHOD FOR CONFIRMING MAINTENANCE RECORD...2764
METHOD FOR OPERATING MAINTENANCE MODE SETTING...2767
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING...2773
DEFAULT MENU...2774
DIAGNOSTIC TESTS MENU...2788
ADJUSTMENT MENU...2798
METHOD FOR PERFORMING NO-INJECTION CRANKING...2832
KOMTRAX SETTINGS MENU...2834
METHOD FOR DISPLAYING SERVICE MESSAGE...2836
METHOD FOR STARTING UP KOMTRAX TERMINAL...2838
ADJUST REARVIEW CAMERA ANGLE...2843
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE...2843
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER...2845
HANDLE BATTERY DISCONNECT SWITCH...2846
TEST DIODES...2847
METHOD FOR TESTING DIODE USING DIGITAL TESTER...2847
METHOD FOR TESTING DIODE USING ANALOG TESTER...2847
AUTO-GREASING DEVICE...2848
BLEED THE AIR OF AUTO-GREASING SYSTEM...2848
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM...2848
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES...2851
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES...2852
Pm CLINIC...2854
Pm CLINIC SERVICE...2854
Pm CLINIC CHECK SHEET: WA270-8...2856
40 TROUBLESHOOTING...2866
CONTENTS...2867
ABBREVIATION LIST...2878
RELATED INFORMATION ON TROUBLESHOOTING...2883
GENERAL TROUBLESHOOTING POINTS...2883
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...2884
SEQUENCE OF EVENTS IN TROUBLESHOOTING...2896
CHECKS BEFORE TROUBLESHOOTING...2898
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...2900
WALK-AROUND CHECK...2900
TESTING IN ACCORDANCE WITH TESTING PROCEDURE...2902
CHECK FUEL LEVEL AND TYPE...2902
FUEL - CHECK FOR FOREIGN MATERIAL...2902
CHECK AdBule/DEF LEVEL AND TYPE...2903
CHECK FUEL PREFILTER...2903
CHECK MAIN FILTER...2905
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE...2906
CHECK COOLANT LEVEL (RESERVOIR TANK)...2907
CHECK CLOGGING OF AIR CLEANER...2908
OUTER ELEMENT - CLEAN...2908
REPLACE ELEMENT...2910
CHECK HYDRAULIC OIL LEVEL...2912
CHECK HYDRAULIC OIL STRAINER...2912
CHECK HYDRAULIC FILTER...2915
CHECK THE OIL LEVEL IN THE TRANSFER CASE...2915
CHECK OIL LEVEL IN FRONT AXLE CASE...2917
CHECK OIL LEVEL IN REAR AXLE CASE...2918
BLEED AIR FROM FUEL SYSTEM...2918
BLEED AIR FROM HYDRAULIC SYSTEM...2918
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod...2918
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION...2924
PROCEDURE FOR TESTING AND TROUBLESHOOTING...2932
SYMPTOM AND TROUBLESHOOTING NUMBERS...2934
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...2938
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM...2940
CONNECTORS LIST AND LAYOUT...2943
CONNECTOR CONTACT IDENTIFICATION...2963
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...3003
FUSE LOCATION TABLE...3009
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)...3012
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR...3016
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT...3018
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])...3024
FAILURE CODES TABLE...3026
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...3045
FAILURE CODE [2F00MA] Failure of Parking Brake Circuit...3045
FAILURE CODE [2F00MB] Failure of Parking Brake Circuit...3048
FAILURE CODE [2G42ZG] Accumulator Oil Pressure Low (Front)...3050
FAILURE CODE [2G43ZG] Accumulator Oil Pressure Low (Rear)...3052
FAILURE CODE [6091NX] HST Oil Filter Clogging...3054
FAILURE CODE [7RHYKA] Fan Motor EPC Sol Output Open Circuit...3056
FAILURE CODE [7RHYKB] Fan Motor EPC Sol Output Ground Fault...3058
FAILURE CODE [7RHYKY] Fan Motor EPC Sol Output Hot Short Circuit...3060
FAILURE CODE [879AKA] A/C Inner Sensor Open Circuit...3062
FAILURE CODE [879AKB] A/C Inner Sensor Short Circuit...3064
FAILURE CODE [879BKA] A/C Outer Sensor Open Circuit...3066
FAILURE CODE [879BKB] A/C Outer Sensor Short Circuit...3068
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit...3070
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit...3072
FAILURE CODE [879DKZ] Sunlight Sensor Open or Short Circuit...3074
FAILURE CODE [879EMC] Ventilation Damper Abnormality...3076
FAILURE CODE [879FMC] Air Mix Damper Abnormality...3077
FAILURE CODE [989FN1] Travel Speed Overrun...3078
FAILURE CODE [989L00] Engine Controller Lock Caution 1...3079
FAILURE CODE [989M00] Engine Controller Lock Caution 2...3080
FAILURE CODE [989N00] Engine Controller Lock Caution 3...3081
FAILURE CODE [A1U0N3] Hydrocarbon Desorb Request 1...3082
FAILURE CODE [A1U0N4] Hydrocarbon Desorb Request 2...3084
FAILURE CODE [AB00KE] Charge Voltage Low...3086
FAILURE CODE [AB00KY] Hot Short of Alternator R Terminal...3088
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)...3090
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR)...3092
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)...3094
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality)...3095
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality)...3096
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality)...3097
FAILURE CODE [AS00R6] Temporary Recovery of Inducement...3098
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5...3099
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning...3100
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning...3101
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution...3102
FAILURE CODE [B@BAZG] Engine Oil Pressure Low...3103
FAILURE CODE [B@BCNS] Engine Coolant Overheat...3104
FAILURE CODE [B@BCZK] Eng Water Level Low...3105
FAILURE CODE [B@C6NS] Brake Oil Temp. Overheat...3107
FAILURE CODE [B@CRNS] HST Oil Temp Overheat...3109
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error...3110
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error...3111
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error...3113
FAILURE CODE [CA131] Throttle Sensor High Error...3115
FAILURE CODE [CA132] Throttle Sensor Low Error...3117
FAILURE CODE [CA144] Coolant Temperature Sensor High Error...3120
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error...3122
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error...3124
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error...3127
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error...3129
FAILURE CODE [CA221] Ambient Pressure Sensor High Error...3131
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error...3133
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error...3135
FAILURE CODE [CA234] Engine Overspeed...3136
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error...3137
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error...3139
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error...3141
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error...3143
FAILURE CODE [CA271] PCV 1 Short Circuit Error...3145
FAILURE CODE [CA272] PCV 1 Open Circuit Error...3147
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error...3149
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error...3151
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error...3153
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error...3155
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error...3157
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error...3159
FAILURE CODE [CA343] Engine Controller Internal Abnormality...3161
FAILURE CODE [CA351] Injectors Drive Circuit Error...3162
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error...3163
FAILURE CODE [CA356] MAF Sensor High Error...3166
FAILURE CODE [CA357] MAF Sensor Low Error...3168
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error...3171
FAILURE CODE [CA428] Water in Fuel Sensor High Error...3172
FAILURE CODE [CA429] Water in Fuel Sensor Low Error...3174
FAILURE CODE [CA431] Idle Validation Sw Error...3176
FAILURE CODE [CA432] Idle Validation Process Error...3179
FAILURE CODE [CA435] Engine Oil Pressure SW Error...3183
FAILURE CODE [CA441] Power Voltage Low Error...3185
FAILURE CODE [CA442] Power Voltage High Error...3187
FAILURE CODE [CA449] Common Rail Pressure High Error 2...3188
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error...3189
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error...3191
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate...3193
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error...3194
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error...3196
FAILURE CODE [CA553] Common Rail Pressure High Error 1...3198
FAILURE CODE [CA555] Crankcase Pressure High Error 1...3199
FAILURE CODE [CA556] Crankcase Pressure High Error 2...3200
FAILURE CODE [CA559] Common Rail Pressure Low Error 1...3201
FAILURE CODE [CA595] Turbocharger Speed High Error 2...3204
FAILURE CODE [CA687] Turbocharger Speed Low Error...3205
FAILURE CODE [CA689] Engine NE Speed Sensor Error...3207
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error...3210
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error...3212
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error...3214
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error...3215
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error...3216
FAILURE CODE [CA778] Engine Backup Speed Sensor Error...3218
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error...3223
FAILURE CODE [CA1664] KDOC Abnormality...3224
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error...3226
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3...3227
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error...3228
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error...3229
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error...3230
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error...3232
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error...3234
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error...3236
FAILURE CODE [CA1691] Defective Regeneration...3237
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error...3240
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error...3243
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error...3244
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error...3246
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error...3249
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error...3251
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error...3252
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error...3253
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error...3256
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error...3259
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error...3261
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error...3264
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error...3267
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error...3269
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error...3273
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error...3275
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1...3277
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2...3280
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error...3285
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error...3286
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error...3289
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error...3291
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2...3293
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error...3294
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error...3297
FAILURE CODE [CA2288] Turbocharger Speed High Error 1...3300
FAILURE CODE [CA2311] lMV Solenoid Error...3301
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error...3302
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error...3305
FAILURE CODE [CA2357] EGR Valve Servo Error...3307
FAILURE CODE [CA2381] KVGT Position Sensor High Error...3308
FAILURE CODE [CA2382] KVGT Position Sensor Low Error...3311
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error...3314
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error...3317
FAILURE CODE [CA2387] KVGT Servo Error...3319
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error...3320
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error...3323
FAILURE CODE [CA2637] KDOC Face Plugging...3325
FAILURE CODE [CA2639] Manual Stationary Regeneration Request...3327
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error...3330
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable...3336
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error...3339
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error...3341
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error...3344
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error...3346
FAILURE CODE [CA3142] SCR Temperature Sensor High Error...3350
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error...3351
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error...3352
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error...3355
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error...3356
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error...3357
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2...3359
FAILURE CODE [CA3165] SCR Outlet Temperature High Error...3365
FAILURE CODE [CA3229] SCR Temperature High Error...3367
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration...3369
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error...3371
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration...3375
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error...3377
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error...3380
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error...3383
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error...3386
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration...3388
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1...3391
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration...3394
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1...3398
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2...3400
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2...3402
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error...3405
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error...3407
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error...3408
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error...3411
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error...3413
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error...3414
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error...3417
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error...3418
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error...3420
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error...3423
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error...3425
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1...3427
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2...3428
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)...3429
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error...3436
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4...3438
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error...3439
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error...3441
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error...3443
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error...3445
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error...3448
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction...3451
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error...3455
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error...3457
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error...3459
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error...3461
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error...3463
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error...3465
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1...3467
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error...3473
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error...3475
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error...3477
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error...3479
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error...3484
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error...3490
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error...3493
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error...3494
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error...3495
FAILURE CODE [CA3741] Common Rail Pressure Valve Trip Error...3498
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error...3499
FAILURE CODE [CA3751] SCR Catalyst Degradation Error...3502
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error...3504
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2...3506
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1...3509
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error...3512
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error...3516
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error...3518
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error...3522
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error...3524
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error...3526
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error...3528
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error...3531
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error...3533
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error...3535
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error...3539
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error...3543
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error...3546
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction...3549
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error...3551
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error...3552
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error...3553
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error...3556
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error...3559
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error...3561
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error...3563
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error...3565
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error...3567
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error...3570
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error...3572
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error...3575
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error...3577
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error...3579
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error...3582
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error...3585
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error...3588
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error...3591
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error...3594
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error...3597
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error...3601
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error...3602
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error...3603
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error...3604
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible...3606
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error...3609
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller)...3612
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error...3614
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error...3617
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error...3619
FAILURE CODE [CA5383] Ash Accumulation High Error...3621
FAILURE CODE [D110L4] Battery Relay Signal Open Circuit...3623
FAILURE CODE [D160KA] Disconnection of Backup Lamp Relay Output...3625
FAILURE CODE [D160KY] Hot Short of Backup Lamp Relay Output...3627
FAILURE CODE [D191KA] Disconnection of Neutral Output Relay...3628
FAILURE CODE [D191KB] Ground Fault of Neutral Output Relay...3629
FAILURE CODE [D191KY] Hot Short of Neutral Output Relay...3630
FAILURE CODE [D192KA] Disconnection of ECSS Solenoid...3631
FAILURE CODE [D192KB] Ground Fault of ECSS Solenoid...3632
FAILURE CODE [D192KY] Hot Short of ECSS Solenoid...3633
FAILURE CODE [D19JKZ] Personal Code Relay Abnormality...3634
FAILURE CODE [D1B0KA] HST Safety Relay Open Circuit...3636
FAILURE CODE [D1B0KB] HST Safety Relay Ground Fault...3638
FAILURE CODE [D1B0KY] HST Safety Relay Hot Short Circuit...3640
FAILURE CODE [D1B0MC] HST Safety Relay Malfunction...3642
FAILURE CODE [D1E6KA] Disconnection of Parking Brake Relay...3644
FAILURE CODE [D1E6KB] Ground Fault of Parking Brake Relay...3646
FAILURE CODE [D1E6KY] Hot Short of Parking Brake Relay...3648
FAILURE CODE [D5ZHKA] Failure of Key SW C Signal...3650
FAILURE CODE [D5ZHKB] Key SW C Signal Short Circuit...3652
FAILURE CODE [D5ZHL6] Disconnection of Key SW C...3654
FAILURE CODE [D811MC] KOMTRAX Error...3655
FAILURE CODE [D862KA] GPS Antenna Open Circuit...3656
FAILURE CODE [D8ALKA] Operating Lamp Open Circuit(KOMTRAX)...3657
FAILURE CODE [D8ALKB] Operating Lamp Short Circuit(KOMTRAX)...3659
FAILURE CODE [D8AQK4] CAN2 Discon (KOMTRAX) 2...3661
FAILURE CODE [D8AQKR] CAN2 Discon (KOMTRAX)...3665
FAILURE CODE [DAF0KT] Abnormality of Non-volatile Memory (MON)...3669
FAILURE CODE [DAF0MB] Monitor ROM Abnormality...3670
FAILURE CODE [DAF0MC] Monitor Error...3671
FAILURE CODE [DAF3KK] Controller Power Source Low (MON)...3672
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit...3674
FAILURE CODE [DAFDKB] Monitor 12V Power Output Short Circuit...3675
FAILURE CODE [DAFGMC] GPS Module Error...3677
FAILURE CODE [DAFLKA] Operating Lamp Open Circuit(MON)...3678
FAILURE CODE [DAFLKB] Operating Lamp Short Circuit(MON)...3680
FAILURE CODE [DAFQKR] CAN2 Discon (Monitor)...3682
FAILURE CODE [DAJ0KK] Controller Power Voltage Low Error (HST)...3687
FAILURE CODE [DAJ0KT] Controller Non-volatile Memory Error (HST)...3690
FAILURE CODE [DAJ0MC] HST Controller Malfunction...3691
FAILURE CODE [DAJ1KA] Key SW ACC Signal Open Circuit (HST)...3692
FAILURE CODE [DAJ2KK] Solenoid Power Voltage Low Error (HST)...3694
FAILURE CODE [DAJ4KB] Self-holding Relay Ground Fault (HST)...3697
FAILURE CODE [DAJ4KZ] Self-holding Relay Open or Hot Short (HST)...3699
FAILURE CODE [DAJ5KX] 5V Sensor 0 Power Voltage Failure (HST)...3701
FAILURE CODE [DAJ6KX] 5V Sensor 1 Power Voltage Failure (HST)...3703
FAILURE CODE [DAJ9KQ] Model Selection Signal Mismatch (HST)...3705
FAILURE CODE [DAJLKA] Operating Lamp Output Open Circuit (HST)...3706
FAILURE CODE [DAJLKB] Operating Lamp Output Short Circuit (HST)...3708
FAILURE CODE [DAJQKR] CAN2 Discon (HST Con)...3710
FAILURE CODE [DAJRKR] CAN1 Discon (HST Con)...3715
FAILURE CODE [DAJRMA] Option Selection Mismatch (HST)...3720
FAILURE CODE [DAZ9KQ] A/C Model Selection Abnormality...3721
FAILURE CODE [DAZQKR] CAN2 Discon (Aircon ECU)...3722
FAILURE CODE [DB2QKR] CAN2 Discon (Engine Con)...3726
FAILURE CODE [DB2RKR] CAN1 Discon (Engine Con)...3732
FAILURE CODE [DD1ALD] Ground Fault of Remote Positioner Set SW...3737
FAILURE CODE [DDAAL6] Discon of Engine Shutdown Secondary Switch...3739
FAILURE CODE [DDB2L4] Stop Lamp Switch Signal Mismatch...3741
FAILURE CODE [DDB6L4] Parking Brake Signal Mismatch...3743
FAILURE CODE [DDD7KA] Speed Adjust Dial Potentio Open or Ground...3745
FAILURE CODE [DDD7KY] Speed Adjust Dial Potentio Hot Short...3747
FAILURE CODE [DDK3KA] FNR SW Input Signal Disconnection...3749
FAILURE CODE [DDK3KB] FNR SW Input Signal Short Circuit...3752
FAILURE CODE [DDK6KA] FNR Lever Input Signal Disconnection...3755
FAILURE CODE [DDK6KB] FNR Lever Input Signal Short Circuit...3758
FAILURE CODE [DDNRLD] Work Equipment Lock Switch Ground Fault...3761
FAILURE CODE [DF10KA] No Signal of Speed Range Input...3763
FAILURE CODE [DF10KB] Plural Signals of Speed Range Input...3766
FAILURE CODE [DGH1KX] HST Oil Temp Sensor Out of Range...3769
FAILURE CODE [DGR2KB] Ground Fault of Brake Oil Temp. Sensor...3771
FAILURE CODE [DGR2KZ] Failure of Brake Oil Temp. Sensor...3773
FAILURE CODE [DHHBKA] HST Pressure Sensor Open or Ground (MA)...3775
FAILURE CODE [DHHBKY] HST Pressure Sensor Hot Short (MA)...3777
FAILURE CODE [DHHCKA] HST Pressure Sensor Open or Ground (MB)...3779
FAILURE CODE [DHHCKY] HST Pressure Sensor Hot Short (MB)...3781
FAILURE CODE [DHPCKA] Boom Press Sensor Open or Ground (Bottom)...3783
FAILURE CODE [DHPCKY] Boom Press Sensor Hot Short (Bottom)...3785
FAILURE CODE [DHPEKA] S/T & Loader Pump Press Sen Open or Ground...3787
FAILURE CODE [DHPEKY] S/T & Loader Pump Press Sensor Hot Short...3789
FAILURE CODE [DHS8KA] Boom Raise PPC Sensor Open or Ground...3791
FAILURE CODE [DHS8KY] Boom Raise PPC Sensor Hot Short...3793
FAILURE CODE [DHS9KA] Boom Lower PPC Sensor Open or Ground...3795
FAILURE CODE [DHS9KY] Boom Lower PPC Sensor Hot Short...3797
FAILURE CODE [DHSDKA] Bucket Dump PPC Sensor Open or Ground...3799
FAILURE CODE [DHSDKY] Bucket Dump PPC Sensor Hot Short...3801
FAILURE CODE [DHSNKA] Bucket Tilt PPC Sensor Open or Ground...3803
FAILURE CODE [DHSNKY] Bucket Tilt PPC Sensor Hot Short...3805
FAILURE CODE [DHT8ZG] Steering Oil Pressure Low...3807
FAILURE CODE [DHTCL6] Failure of HST Oil Filter Sensor Circuit...3808
FAILURE CODE [DJF1KA] Disconnection of Fuel Level Sensor...3810
FAILURE CODE [DK55KA] Failure of FNR Lever Potentio...3811
FAILURE CODE [DK55KY] Hot Short of FNR Lever Potentio Circuit...3813
FAILURE CODE [DK55L5] Failure of FNR Lever Potentio...3815
FAILURE CODE [DK5DKA] Failure of 3rd Lever Potentio (Main)...3816
FAILURE CODE [DK5DKY] Hot Short of 3rd Lever Potentio (Main)...3819
FAILURE CODE [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree...3822
FAILURE CODE [DK5EKA] Failure of 3rd Lever Potentio (Sub)...3826
FAILURE CODE [DK5EKY] Hot Short of 3rd Lever Potentio (Sub)...3829
FAILURE CODE [DK70KA] Inching Sensor Open or Ground...3832
FAILURE CODE [DK70KY] Inching Sensor Hot Short Circuit...3834
FAILURE CODE [DKA0KA] Failure of Boom Angle Sensor...3836
FAILURE CODE [DKA0KY] Hot Short of Boom Angle Sensor Circuit...3839
FAILURE CODE [DKA0L0] Boom Angle Sensor Dislocation...3841
FAILURE CODE [DLM3KA] Disconnection of Radiator Fan Speed Sensor...3843
FAILURE CODE [DLM3LC] Failure of Radiator Fan Speed Sensor...3844
FAILURE CODE [DLT3KX] Speed Sens Open or Ground or Hot Short (B)...3846
FAILURE CODE [DLT4KX] Speed Sens Open or Ground or Hot Short (A)...3848
FAILURE CODE [DLT4L0] Travel Speed Sensor Failure...3850
FAILURE CODE [DLT4LC] Speed Sens Open or Ground or Hot (A or B)...3851
FAILURE CODE [DPQ1KR] LIN Discon (Switch Panel)...3853
FAILURE CODE [DPQ2KR] LIN Discon (LED Unit)...3856
FAILURE CODE [DPQ3KR] LIN Discon (Rear View Monitor)...3859
FAILURE CODE [DSJ0KR] CAN2 Discon (Meter Unit)...3863
FAILURE CODE [DT22KB] Ground Fault of Work Equip. Lock Indic...3868
FAILURE CODE [DV00KB] Ground Fault of Buzzer Output...3870
FAILURE CODE [DW26KA] Motor 2 Solenoid Open Circuit...3871
FAILURE CODE [DW26KB] Motor 2 Solenoid Ground Fault...3873
FAILURE CODE [DW26KY] Motor 2 Solenoid Hot Short Circuit...3875
FAILURE CODE [DW4BKA] Parking Brake Valve Output Open Circuit...3877
FAILURE CODE [DW4BKB] Parking Brake Valve Output Ground Fault...3879
FAILURE CODE [DW4BKY] Parking Brake Valve Output Hot Short...3881
FAILURE CODE [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt)...3882
FAILURE CODE [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt)...3884
FAILURE CODE [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt)...3886
FAILURE CODE [DWM1KA] Disconnection of Neutral Lock Solenoid...3888
FAILURE CODE [DWM1KB] Ground Fault of Neutral Lock Solenoid...3889
FAILURE CODE [DWM1KY] Hot Short of Neutral Lock Solenoid...3891
FAILURE CODE [DWN6KA] Disconnection of Detent Solenoid (Boom)...3892
FAILURE CODE [DWN6KB] Ground Fault of Detent Solenoid (Boom)...3894
FAILURE CODE [DWN6KY] Hot Short of Detent Solenoid (Boom)...3896
FAILURE CODE [DWN8KA] Hot Short of Parking Brake Relay...3897
FAILURE CODE [DWN8KB] Ground Fault of Detent Solenoid (Bucket)...3898
FAILURE CODE [DWN8KY] Hot Short of Detent Solenoid (Bucket)...3899
FAILURE CODE [DX19KA] Motor 1 Solenoid Open Circuit...3900
FAILURE CODE [DX19KB] Motor 1 Solenoid Ground Fault...3902
FAILURE CODE [DX19KY] Motor 1 Solenoid Hot Short Circuit...3904
FAILURE CODE [DX20KA] Clutch EPC Solenoid Open Circuit...3906
FAILURE CODE [DX20KB] Clutch EPC Solenoid Ground Fault...3908
FAILURE CODE [DX20KY] Clutch EPC Solenoid Hot Short Circuit...3910
FAILURE CODE [DXAWKA] HST Pump EPC Solenoid Open Circuit...3911
FAILURE CODE [DXAWKB] HST Pump EPC Solenoid Ground Fault...3914
FAILURE CODE [DXAWKY] HST Pump EPC Solenoid Hot Short Circuit...3917
FAILURE CODE [DXH7KA] Reverse Solenoid Open Circuit...3920
FAILURE CODE [DXH7KB] Reverse Solenoid Ground Fault...3922
FAILURE CODE [DXH7KY] Reverse Solenoid Hot Short Circuit...3924
FAILURE CODE [DXH8KA] Forward Solenoid Open Circuit...3926
FAILURE CODE [DXH8KB] Forward Solenoid Ground Fault...3928
FAILURE CODE [DXH8KY] Forward Solenoid Hot Short Circuit...3930
FAILURE CODE [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)...3932
FAILURE CODE [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)...3934
FAILURE CODE [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)...3936
FAILURE CODE [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)...3937
FAILURE CODE [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)...3939
FAILURE CODE [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)...3941
FAILURE CODE [H2K0KA] Failure of Quick Coupler Lock Signal...3942
FAILURE CODE [H2K0KY] Hot Short of Quick Coupler Lock Signal...3944
FAILURE CODE [J141N1] Steering Pump Overrun...3946
FAILURE CODE [LA00L3] Failure of Fan Reverse...3947
FAILURE CODE [M100N1] HST Pump Overrun...3948
FAILURE CODE [M400N1] HST Motor 1 Overrun...3949
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...3950
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...3950
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...3958
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...3961
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...3964
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING...3966
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING...3969
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)...3971
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY...3973
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL...3975
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL...3978
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL...3982
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY...3984
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION...3987
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL...3990
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY...3993
E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS...3994
E-17 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY...3997
E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED...4001
E-19 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL...4005
E-20 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP...4007
E-21 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION...4009
E-22 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...4013
E-23 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...4014
E-24 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP...4015
E-25 WHEN THE INCHING PEDAL IS DEPRESSED, INCHING FUNCTION DOES NOT WORK OR WHILE THE PEDAL HAS NOT BEEN DEPRESSED, INCHING FUNCTION OPERATES...4016
E-26 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL...4018
E-27 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL...4020
E-28 ALARM BUZZER DOES NOT SOUND...4021
E-29 ALARM BUZZER DOES NOT STOP SOUNDING...4023
E-30 WHEN THE EMERGENCY HST PUMP DRIVE SWITCH IS OPERATED, IT DOES NOT WORK OR WHEN THE EMERGENCY HST PUMP DRIVE SWITCH IS NOT OPERATED, IT WORKS...4024
E-31 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH...4027
E-32 THE REMOTE POSITIONER DOES NOT WORK OR CANNOT BE RELEASED...4029
E-33 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED...4031
E-34 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED...4034
E-35 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED...4038
E-36 PZ AUTO TILT-IN DOES NOT WORK...4040
E-37 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX. TRACTION SWITCH IS TURNED ON...4043
E-38 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED...4045
E-39 HORN DOES NOT SOUND...4047
E-40 HORN DOES NOT STOP SOUNDING...4050
E-41 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS...4052
E-42 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT...4054
E-43 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)...4058
E-44 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT...4062
E-45 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)...4066
E-46 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT...4070
E-47 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)...4072
E-48 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT...4074
E-49 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)...4076
E-50 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT...4078
E-51 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT...4083
E-52 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT...4087
E-53 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT...4090
E-54 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)...4093
E-55 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT...4096
E-56 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)...4100
E-57 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED...4104
E-58 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED (FOR EUROPEAN UNION)...4108
E-59 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT...4112
E-60 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT (FOR EUROPEAN UNION)...4116
E-61 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND...4120
E-62 FRONT WIPER DOES NOT OPERATE...4122
E-63 REAR WIPER DOES NOT OPERATE...4126
E-64 WINDOW WASHER DOES NOT OPERATE...4129
E-65 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...4132
E-66 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP...4133
E-67 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP...4134
E-68 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP...4135
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...4136
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...4136
FAILURE MODE AND CAUSE TABLE...4137
H-1 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE...4151
H-2 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY)...4154
H-3 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY)...4155
H-4 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS LOW...4156
H-5 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE NORMALLY)...4160
H-6 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD NORMALLY)...4161
H-7 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...4162
H-8 MACHINE DOES NOT TURN...4164
H-9 STEERING WHEEL IS HEAVY TO OPERATE...4166
H-10 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS...4168
H-11 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS...4169
H-12 WHEEL BRAKES DO NOT WORK OR ARE WEAK...4170
H-13 WHEEL BRAKES ARE NOT RELEASED OR DRAG...4172
H-14 PARKING BRAKE DOES NOT WORK OR IT IS WEAK...4173
H-15 PARKING BRAKE IS NOT RELEASED OR DRAGS...4174
H-16 BOOM DOES NOT RISE...4176
H-17 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE...4179
H-18 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT...4182
H-19 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND...4183
H-20 HYDRAULIC DRIFT OF BOOM IS LARGE...4185
H-21 BOOM MOVES UP AND DOWN DURING OPERATION...4186
H-22 BUCKET DOES NOT TILT BACK...4187
H-23 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE...4190
H-24 BUCKET DECELERATES DURING TILT-BACK OPERATION...4193
H-25 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND...4194
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE...4196
H-27 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)...4197
H-28 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE...4198
H-29 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...4199
H-30 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS...4200
H-31 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...4202
H-32 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES...4203
H-33 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)...4204
H-34 UNUSUAL NOISE IS HEARD FROM AROUND FAN...4207
TROUBLESHOOTING OF ENGINE (S-MODE)...4208
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...4208
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...4209
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...4210
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...4211
S-4 ENGINE STARTABILITY IS POOR...4213
S-5 ENGINE DOES NOT PICK UP SMOOTHLY...4215
S-6 ENGINE STOPS DURING OPERATION...4217
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE...4219
S-8 ENGINE LACKS POWER...4220
S-9 KDPF GETS CLOGGED IN A SHORT TIME...4222
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE...4224
S-11 OIL BECOMES CONTAMINATED QUICKLY...4225
S-12 FUEL CONSUMPTION IS EXCESSIVE...4226
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...4227
S-14 OIL PRESSURE DROPS...4228
S-15 FUEL MIXES INTO ENGINE OIL...4230
S-16 WATER MIXES INTO ENGINE OIL (MILKY)...4231
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...4232
S-18 UNUSUAL NOISE IS HEARD...4233
S-19 VIBRATION IS EXCESSIVE...4234
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...4235
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...4236
S-22 ACTIVE REGENERATION TAKES TIME...4238
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...4239
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE...4240
S-25 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...4242
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM...4243
OUTLINE OF FAILURE DISPLAY...4243
TROUBLESHOOTING FOR FCS...4244
REPLACEMENT OF PUMP ELEMENT...4245
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM...4246
REPLACEMENT OF AUTO-GREASING CONTROLLER...4248
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING...4249
50 DISASSEMBLY AND ASSEMBLY...4250
CONTENTS...4251
ABBREVIATION LIST...4255
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...4260
HOW TO READ THIS MANUAL...4260
COATING MATERIALS LIST...4262
SPECIAL TOOLS LIST...4267
SKETCHES OF SPECIAL TOOLS...4290
ENGINE AND COOLING SYSTEM...4310
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...4310
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY...4311
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...4316
REMOVE AND INSTALL INJECTOR ASSEMBLY...4323
METHOD FOR REMOVING INJECTOR ASSEMBLY...4323
METHOD FOR INSTALLING INJECTOR ASSEMBLY...4331
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...4341
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...4342
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY...4353
REMOVE AND INSTALL EGR VALVE ASSEMBLY...4368
METHOD FOR REMOVING EGR VALVE ASSEMBLY...4368
METHOD FOR INSTALLING EGR VALVE ASSEMBLY...4372
REMOVE AND INSTALL EGR COOLER ASSEMBLY...4376
METHOD FOR REMOVING EGR COOLER ASSEMBLY...4376
METHOD FOR INSTALLING EGR COOLER ASSEMBLY...4379
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY...4384
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY...4384
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY...4386
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT...4389
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT...4389
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT...4390
REMOVE AND INSTALL ALTERNATOR BELT...4392
METHOD FOR REMOVING ALTERNATOR BELT...4392
METHOD FOR INSTALLING ALTERNATOR BELT...4395
REMOVE AND INSTALL ALTERNATOR ASSEMBLY...4397
METHOD FOR REMOVING ALTERNATOR ASSEMBLY...4397
METHOD FOR INSTALLING ALTERNATOR ASSEMBLY...4399
REMOVE AND INSTALL RADIATOR ASSEMBLY...4404
METHOD FOR REMOVING RADIATOR ASSEMBLY...4404
METHOD FOR INSTALLING RADIATOR ASSEMBLY...4407
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...4411
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...4411
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...4414
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...4418
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...4418
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY...4420
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...4422
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY...4422
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...4423
REMOVE AND INSTALL ENGINE ASSEMBLY...4425
METHOD FOR REMOVING ENGINE ASSEMBLY...4426
METHOD FOR INSTALLING ENGINE ASSEMBLY...4444
REMOVE AND INSTALL ENGINE FRONT OIL SEAL...4464
METHOD FOR REMOVING ENGINE FRONT OIL SEAL...4464
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL...4466
REMOVE AND INSTALL ENGINE REAR OIL SEAL...4469
METHOD FOR REMOVING ENGINE REAR OIL SEAL...4470
METHOD FOR INSTALLING ENGINE REAR OIL SEAL...4471
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY...4475
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY...4475
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...4481
REMOVE AND INSTALL FUEL TANK ASSEMBLY...4488
METHOD FOR REMOVING FUEL TANK ASSEMBLY...4488
METHOD FOR INSTALLING FUEL TANK ASSEMBLY...4492
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY...4497
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY...4498
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...4505
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...4511
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...4511
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...4513
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...4516
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...4516
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR...4517
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER...4519
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER...4519
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER...4520
REMOVE AND INSTALL KDPF ASSEMBLY...4521
METHOD FOR REMOVING KDPF ASSEMBLY...4522
METHOD FOR INSTALLING KDPF ASSEMBLY...4531
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY...4543
METHOD FOR DISASSEMBLING KDPF ASSEMBLY...4543
METHOD FOR ASSEMBLING KDPF ASSEMBLY...4548
REMOVE AND INSTALL SCR ASSEMBLY...4553
METHOD FOR REMOVING SCR ASSEMBLY...4554
METHOD FOR INSTALLING SCR ASSEMBLY...4564
REMOVE AND INSTALL KDPF, SCR ASSEMBLY...4577
METHOD FOR REMOVING KDPF, SCR ASSEMBLY...4578
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY...4588
REMOVE AND INSTALL KCCV ASSEMBLY...4603
METHOD FOR REMOVING KCCV ASSEMBLY...4603
METHOD FOR INSTALLING KCCV ASSEMBLY...4605
REMOVE AND INSTALL VGT ASSEMBLY...4608
METHOD FOR REMOVING VGT ASSEMBLY...4608
METHOD FOR INSTALLING VGT ASSEMBLY...4615
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE...4624
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...4625
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE...4630
REMOVE AND INSTALL AdBlue/DEF INJECTOR...4637
METHOD FOR REMOVING AdBlue/DEF INJECTOR...4637
METHOD FOR INSTALLING AdBlue/DEF INJECTOR...4639
REMOVE AND INSTALL AdBlue/DEF PUMP...4643
METHOD FOR REMOVING AdBlue/DEF PUMP...4643
METHOD FOR INSTALLING AdBlue/DEF PUMP...4646
REMOVE AND INSTALL AdBlue/DEF HOSE...4650
METHOD FOR REMOVING AdBlue/DEF HOSE...4650
METHOD FOR INSTALLING AdBlue/DEF HOSE...4660
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...4670
METHOD FOR REMOVING AIR CLEANER ASSEMBLY...4670
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...4673
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...4676
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY...4677
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...4679
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...4682
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...4682
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...4684
POWER TRAIN...4687
REMOVE AND INSTALL HST PUMP ASSEMBLY...4687
METHOD FOR REMOVING HST PUMP ASSEMBLY...4688
METHOD FOR INSTALLING HST PUMP ASSEMBLY...4694
REMOVE AND INSTALL HST MOTOR1 ASSEMBLY...4703
METHOD FOR REMOVING HST MOTOR1 ASSEMBLY...4703
METHOD FOR INSTALLING HST MOTOR1 ASSEMBLY...4706
REMOVE AND INSTALL HST MOTOR2 ASSEMBLY...4709
METHOD FOR REMOVING HST MOTOR2 ASSEMBLY...4710
METHOD FOR INSTALLING HST MOTOR2 ASSEMBLY...4718
REMOVE AND INSTALL TRANSFER ASSEMBLY...4727
METHOD FOR REMOVING TRANSFER ASSEMBLY...4728
METHOD FOR INSTALLING TRANSFER ASSEMBLY...4732
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY...4737
METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY...4740
METHOD FOR ASSEMBLING TRANSFER ASSEMBLY...4759
REMOVE AND INSTALL FRONT AXLE ASSEMBLY...4784
METHOD FOR REMOVING FRONT AXLE ASSEMBLY...4784
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY...4786
REMOVE AND INSTALL REAR AXLE ASSEMBLY...4789
METHOD FOR REMOVING REAR AXLE ASSEMBLY...4789
METHOD FOR INSTALLING REAR AXLE ASSEMBLY...4793
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY...4797
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY...4798
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY...4806
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY...4816
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY...4817
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY...4830
UNDERCARRIAGE AND FRAME...4850
REMOVE AND INSTALL CENTER HINGE PIN...4850
METHOD FOR REMOVING CENTER HINGE PIN...4851
METHOD FOR INSTALLING CENTER HINGE PIN...4857
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...4868
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY...4868
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY...4874
HYDRAULIC SYSTEM...4879
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...4879
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY...4880
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...4890
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY...4899
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY...4899
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY...4905
WORK EQUIPMENT...4911
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...4911
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY...4912
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...4916
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY...4927
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...4928
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...4932
CAB AND ITS ATTACHMENTS...4939
REMOVE AND INSTALL OPERATOR'S CAB AND FLOOR FRAME ASSEMBLY...4939
METHOD FOR REMOVING OPERATOR'S CAB AND FLOOR FRAME ASSEMBLY...4940
METHOD FOR INSTALLING OPERATOR'S CAB AND FLOOR FRAME ASSEMBLY...4947
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)...4956
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)...4956
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)...4957
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...4966
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...4966
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY...4972
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY...4979
METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY...4979
METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY...4979
REMOVE AND INSTALL SEAT BELT...4981
METHOD FOR REMOVING SEAT BELT...4981
METHOD FOR INSTALLING SEAT BELT...4981
ELECTRICAL SYSTEM...4983
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...4983
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...4983
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY...4987
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY...4992
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY...4992
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY...4994
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY...4996
METHOD FOR REMOVING AIR CONDITIONER CONTROLLER ASSEMBLY...4996
METHOD FOR INSTALLING AIR CONDITIONER CONTROLLER ASSEMBLY...4997
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY...4999
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY...4999
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY...5002
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...5004
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...5004
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...5007
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...5010
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR...5010
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...5011
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...5012
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR...5012
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR...5013
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR...5015
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR...5015
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR...5017
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR...5020
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR...5020
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR...5023
REMOVE AND INSTALL SCR TEMPERATURE SENSOR...5026
METHOD FOR REMOVING SCR TEMPERATURE SENSOR...5026
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR...5027
REMOVE AND INSTALL AMMONIA SENSOR...5029
METHOD FOR REMOVING AMMONIA SENSOR...5029
METHOD FOR INSTALLING AMMONIA SENSOR...5031
REMOVE AND INSTALL SCR OUTLET NOx SENSOR...5034
METHOD FOR REMOVING SCR OUTLET NOx SENSOR...5034
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR...5036
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...5039
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...5039
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY...5040
60 MAINTENANCE STANDARD...5042
CONTENTS...5043
ABBREVIATION LIST...5044
ENGINE AND COOLING SYSTEM...5049
MAINTENANCE STANDARD OF ENGINE MOUNT...5049
MAINTENANCE STANDARD OF DAMPER...5050
MAINTENANCE STANDARD OF COOLING FAN MOTOR...5051
POWER TRAIN...5053
MAINTENANCE STANDARD OF DRIVE SHAFT...5053
MAINTENANCE STANDARD OF TRANSFER...5054
MAINTENANCE STANDARD OF TRANSFER MOUNT...5062
MAINTENANCE STANDARD OF FRONT AXLE...5063
MAINTENANCE STANDARD OF REAR AXLE...5064
MAINTENANCE STANDARD OF FRONT TORQUE PROPORTIONING DIFFERENTIAL...5065
MAINTENANCE STANDARD OF REAR TORQUE PROPORTIONING DIFFERENTIAL...5067
MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL...5069
MAINTENANCE STANDARD OF FRONT FINAL DRIVE...5071
MAINTENANCE STANDARD OF REAR FINAL DRIVE...5073
STEERING SYSTEM...5075
MAINTENANCE STANDARD OF STEERING COLUMN...5075
MAINTENANCE STANDARD OF PRIORITY VALVE...5076
MAINTENANCE STANDARD OF STEERING CYLINDER...5077
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE...5080
BRAKE SYSTEM...5081
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE...5081
MAINTENANCE STANDARD OF SLACK ADJUSTER...5082
MAINTENANCE STANDARD OF FRONT BRAKE...5083
MAINTENANCE STANDARD OF REAR BRAKE...5084
MAINTENANCE STANDARD OF PARKING BRAKE...5085
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE...5087
UNDERCARRIAGE AND FRAME...5088
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...5088
HYDRAULIC SYSTEM...5094
MAINTENANCE STANDARD OF HYDRAULIC TANK...5094
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP...5095
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP...5096
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND WORK EQUIPMENT PUMP...5099
MAINTENANCE STANDARD OF CONTROL VALVE...5100
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE...5112
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE...5114
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE...5116
WORK EQUIPMENT...5117
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...5117
MAINTENANCE STANDARD OF BUCKET...5121
MAINTENANCE STANDARD OF LIFT CYLINDER...5122
MAINTENANCE STANDARD OF BUCKET CYLINDER...5123
CAB AND ITS ATTACHMENTS...5124
MAINTENANCE STANDARD OF CAB MOUNT...5124
80 APPENDIX...5126
CONTENTS...5127
ABBREVIATION LIST...5129
AIR CONDITIONER SYSTEM...5134
PRECAUTIONS FOR REFRIGERANT...5134
AIR CONDITIONER COMPONENT...5135
SPECIFICATIONS OF AIR CONDITIONER...5137
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...5138
OUTLINE OF REFRIGERATION CYCLE...5139
COMPONENT PARTS OF AIR CONDITIONER SYSTEM...5141
AIR CONDITIONER UNIT...5141
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...5141
FUNCTION OF AIR CONDITIONER UNIT...5142
COMPONENT PARTS OF AIR CONDITIONER UNIT...5143
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...5143
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...5143
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT...5144
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT...5144
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT...5144
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...5144
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...5144
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...5144
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...5145
FUNCTION OF DUAL PRESSURE SWITCH...5145
AIR CONDITIONER CONTROLLER...5146
STRUCTURE OF AIR CONDITIONER CONTROLLER...5146
COMPRESSOR...5147
STRUCTURE OF COMPRESSOR...5147
SPECIFICATIONS OF COMPRESSOR...5147
FUNCTION OF COMPRESSOR...5147
CONDENSER...5148
STRUCTURE OF CONDENSER...5148
SPECIFICATIONS OF CONDENSER...5148
FUNCTION OF CONDENSER...5148
RECEIVER DRIER...5149
STRUCTURE OF RECEIVER DRIER...5149
SPECIFICATIONS OF RECEIVER DRIER...5149
FUNCTION OF RECEIVER DRIER...5149
SENSORS FOR AIR CONDITIONER SYSTEM...5150
FUNCTION OF SUNLIGHT SENSOR...5150
FUNCTION OF AMBIENT TEMPERATURE SENSOR...5150
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...5151
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...5153
AIR CONDITIONER SYSTEM DIAGRAM...5156
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...5157
FUNCTION OF AIR CONDITIONER CONTROLLER...5158
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...5159
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...5165
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR...5166
CHECK TEMPERATURE CONTROL FUNCTION...5167
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION...5167
TEST VENT (MODE) CHANGEOVER...5169
METHOD FOR TESTING VENT (MODE) CHANGEOVER...5169
TESTING FRESH/RECIRC AIR CHANGEOVER...5171
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER...5171
TEST EVAPORATOR TEMPERATURE SENSOR...5173
TEST RELAYS...5175
METHOD FOR TESTING RELAYS...5175
AIR CONDITIONER TROUBLESHOOTING CHART 1...5177
AIR CONDITIONER TROUBLESHOOTING CHART 2...5178
FAILURE CODE [879AKA] A/C Inner Sensor Open Circuit...5181
FAILURE CODE [879AKB] A/C Inner Sensor Short Circuit...5183
FAILURE CODE [879BKA] A/C Outer Sensor Open Circuit...5185
FAILURE CODE [879BKB] A/C Outer Sensor Short Circuit...5187
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit...5189
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit...5191
FAILURE CODE [879DKZ] Sunlight Sensor Open or Short Circuit...5193
FAILURE CODE [879EMC] Ventilation Damper Abnormality...5195
FAILURE CODE [879FMC] Air Mix Damper Abnormality...5196
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...5197
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...5200
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...5203
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...5207
TROUBLESHOOTING USING GAUGE PRESSURE...5209
CONNECTION OF SERVICE TOOL...5212
METHOD FOR CONNECTING SERVICE TOOL...5213
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...5214
HANDLE COMPRESSOR OIL...5216
90 CIRCUIT DIAGRAMS...5218
CONTENTS...5219
ABBREVIATION LIST...5220
HYDRAULIC CIRCUIT DIAGRAM...5225
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...5225
HYDRAULIC CIRCUIT DIAGRAM...5230
HYDRAULIC AUTO-GREASING DIAGRAM...5231
ELECTRICAL CIRCUIT DIAGRAM...5232
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...5232
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/7)...5236
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/7)...5237
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/7)...5238
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/7)...5239
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/7)...5240
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/7)...5241
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/7)...5242
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/9)...5243
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/9)...5244
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/9)...5245
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/9)...5246
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/9)...5247
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/9)...5248
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/9)...5249
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/9)...5250
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/9)...5251
INDEX...5252
SEN06255-01 - Wheel Loader WA270-7 Shop Manual...5276
Cover...5276
00 Index and foreword ...5278
Index ...5279
Foreword, safety and general information ...5294
Important safety notice ...5294
How to read the shop manual ...5301
Explanation of terms for maintenance standard ...5303
Handling equipment of fuel system devices ...5305
Handling of intake system parts ...5306
Handling of hydraulic equipment ...5307
Method of disconnecting and connecting of push-pull type coupler ...5309
Handling of electrical equipment ...5312
How to read electric wire code ...5320
Precautions when performing operation ...5323
Practical use of KOMTRAX ...5328
Standard tightening torque table ...5329
List of abbreviation ...5335
Conversion table ...5340
01 Specification ...5346
Table of contents ...5347
Specifications ...5348
Specification drawing ...5348
Specifications ...5350
Weight table ...5355
Table of fuel, coolant, and lubricants ...5357
10 Structure and function ...5358
Table of contents ...5359
Engine and cooling system ...5361
Engine related parts ...5361
KVGT ...5363
EGR system piping drawing ...5370
EGR system circuit diagram ...5372
EGR valve ...5374
EGR cooler ...5376
KCCV layout drawing ...5377
KCCV ventilator ...5379
KDPF ...5381
Cooling system ...5385
Cooling fan motor ...5387
Power train ...5397
Power train system ...5397
Layout of power train parts ...5399
Damper ...5400
HST pump ...5401
HST motor1 ...5414
HST motor2 ...5416
Transfer ...5421
Clutch solenoid valve ...5428
Drive shaft ...5430
Axle ...5431
Differential ...5433
Torque proportional differential ...5437
Limited slip differential ...5439
Final drive ...5444
Steering system ...5447
Layout of steering devices ...5447
Steering column ...5448
Priority valve ...5449
Cushion valve ...5453
Emergency steering valve ...5454
Orbitrol valve ...5457
2way restrictor valve ...5463
Brake system ...5464
Layout of brake parts ...5464
Brake accumulator charge valve ...5466
Brake valve ...5471
Brake accumulator ...5475
Slack adjuster ...5476
Brake ...5478
Parking brake control ...5481
Parking brake ...5482
Parking brake solenoid valve ...5483
Undercarriage and frame ...5485
Axle mount ...5485
Center hinge pin ...5487
Tire ...5488
Hydraulic system ...5490
Hydraulic component layout ...5490
Work equipment control ...5492
Hydraulic tank ...5493
Double type gear pump ...5496
Steering and work equipment pump ...5497
Control valve ...5509
CLSS ...5519
Hydraulic circuit diagram and names of valves ...5523
Self-pressure reducing valve ...5536
Work equipment PPC valve ...5541
Work equipment lock solenoid valve ...5549
PPC circuit accumulator ...5550
ECSS accumulator ...5551
Work equipment ...5552
Work equipment linkage ...5552
Bucket ...5553
Cab and its attachments ...5554
ROPS cab ...5554
Cab mount ...5556
Electrical system ...5557
Engine control system ...5557
Preheating system ...5560
Engine output limit function ...5562
Automatic warm-up function ...5563
Parking brake control system ...5564
System operating lamp function ...5568
Battery disconnect switch function ...5569
HST controller system ...5571
Machine monitor system ...5611
Rearview monitor system ...5632
KOMTRAX system ...5635
System component parts ...5638
Sensor ...5661
20 Standard value tables ...5682
Table of contents ...5683
Standard service value table ...5684
Standard value table for engine ...5684
Standard value table for machine ...5686
Standard value table for electrical system ...5698
30 Testing and adjusting ...5708
Table of contents ...5709
Related information on testing and adjusting ...5711
Tools for testing and adjusting ...5711
Sketch of tools for testing and adjusting ...5717
Engine and cooling system ...5718
Testing engine speed ...5718
Testing boost pressure ...5719
Testing exhaust gas temperature ...5721
Testing exhaust gas color ...5722
Testing and adjusting valve clearance ...5724
Testing compression pressure ...5726
Testing blowby pressure ...5730
Testing engine oil pressure ...5731
Testing EGR valve and KVGT driving oil pressure ...5732
Testing fuel pressure ...5733
Testing fuel discharge, return and leakage ...5737
Bleeding air from fuel system ...5742
Testing fuel circuit for leakage ...5744
Handling cylinder cutout mode operation ...5745
Handling no-injection cranking operation ...5746
Testing of KDPF and muffler stack for looseness and damage ...5747
Testing of installed condition of cylinder heads and manifolds ...5748
Testing engine piping for damage and looseness ...5749
Testing and adjusting air conditioner compressor belt tension ...5750
Replacing alternator belt ...5751
Power train ...5752
Testing oil leakage from axle final drive ...5752
Testing drive shaft for looseness, backlash, and damage ...5753
Testing accelerator pedal ...5754
Testing and adjusting HST oil pressure ...5755
Testing transfer clutch control pressure ...5758
Steering system ...5759
Testing directional lever ...5759
Testing steering wheel ...5760
Testing work equipment control lever ...5762
Testing and adjusting steering circuit oil pressure ...5764
Bleeding air from steering cylinder circuit ...5766
Brake system ...5767
Testing brake pedal ...5767
Testing braking performance ...5768
Testing and adjusting of accumulator charge pressure ...5769
Testing wheel brake oil pressure ...5771
Testing lowering of wheel brake pressure ...5772
Testing wear of wheel brake disc ...5774
Bleeding air from wheel brake circuit ...5775
Releasing remaining pressure in brake accumulator circuit ...5776
Testing parking brake performance ...5777
Testing wear of parking brake disc ...5778
Testing parking brake release pressure ...5779
Method of releasing parking brake manually ...5780
Hydraulic system ...5781
Testing cooling fan speed ...5781
Testing cooling fan pump circuit oil pressure ...5782
Bleeding air from hydraulic fan circuit ...5784
Testing and adjusting work equipment PPC oil pressure ...5785
Testing and adjusting work equipment oil pressure ...5787
Bleeding air from work equipment circuit ...5791
Releasing remaining pressure from work equipment circuit ...5792
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ...5794
Work equipment ...5798
Testing and adjusting bucket positioner and bucket proximity switch ...5798
Testing and adjusting boom position detection lever ...5800
Electrical system ...5801
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...5801
Special functions of machine monitor ...5802
Adjusting rearview camera angle ...5880
Handling voltage circuit of engine controller ...5881
Handling battery disconnect switch ...5882
Testing diodes ...5883
Pm clinic ...5884
Pm Clinic service ...5884
Check sheet ...5885
40 Troubleshooting ...5890
Table of contents ...5891
Related information on troubleshooting ...5900
Troubleshooting points ...5900
Sequence of events in troubleshooting ...5902
Checks before troubleshooting ...5904
Inspection procedure before troubleshooting ...5906
Preparation for troubleshooting of electrical system ...5923
Classification and procedures for troubleshooting ...5929
Symptom and troubleshooting numbers ...5932
Information described in troubleshooting table ...5935
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ...5937
Connector list and layout ...5940
Connector contact identification ...5954
T-branch box and T-branch adapter table ...5992
Fuse location table ...5997
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ...6000
Precautions when performing troubleshooting of machine monitor ...6003
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ...6005
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ...6010
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ...6011
Failure codes table ...6012
Troubleshooting by failure code (Display of code) ...6024
Failure code [2F00MA] Failure of Parking Brake Circuit ...6024
Failure code [2F00MB] Malfunction of Parking Brake ...6027
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...6029
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ...6031
Failure code [6091NX] HST Oil Filter Clogging ...6033
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ...6035
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. ...6037
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ...6039
Failure code [879AKA] A/C Inner Sensor Open Circuit ...6041
Failure code [879AKB] A/C Inner Sensor Short Circuit ...6042
Failure code [879BKA] A/C Outer Sensor Open Circuit ...6043
Failure code [879BKB] A/C Outer Sensor Short Circuit ...6044
Failure code [879CKA] Ventilating Sensor Open Circuit ...6045
Failure code [879CKB] Ventilating Sensor Short Circuit ...6046
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...6047
Failure code [879EMC] Ventilation Damper Abnormality ...6048
Failure code [879FMC] Air Mix Damper Abnormality ...6049
Failure code [989L00] Engine Controller Lock Caution 1 ...6050
Failure code [989M00] Engine Controller Lock Caution 2 ...6051
Failure code [989N00] Engine Controller Lock Caution 3 ...6052
Failure code [A1U0N3] HC Desorb Request 1 ...6053
Failure code [A1U0N4] HC Desorb Request 2 ...6055
Failure code [B@BAZG] Eng Oil Press Low ...6057
Failure code [B@BCNS] Eng Water Overheat ...6058
Failure code [B@BCZK] Eng Water Level Low ...6059
Failure code [B@CRNS] HST Oil Temp. Overheat ...6061
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ...6062
Failure code [CA122] Chg Air Press Sensor High Error ...6063
Failure code [CA123] Chg Air Press Sensor Low Error ...6065
Failure code [CA131] Throttle Sensor High Error ...6067
Failure code [CA132] Throttle Sensor Low Error ...6069
Failure code [CA144] Coolant Temp Sens High Error ...6071
Failure code [CA145] Coolant Temp Sens Low Error ...6073
Failure code [CA153] Chg Air Temp Sensor High Error ...6075
Failure code [CA154] Chg Air Temp Sensor Low Error ...6077
Failure code [CA187] Sensor 2 Supply Volt Low Error ...6079
Failure code [CA221] Ambient Press Sensor High Error ...6081
Failure code [CA222] Ambient Press Sensor Low Error ...6083
Failure code [CA227] Sensor 2 Supply Volt High Error ...6085
Failure code [CA234] Eng Overspeed ...6086
Failure code [CA238] Ne Speed Sensor Supply Volt Error ...6087
Failure code [CA239] Ne Speed Sens Supply Volt High Error ...6088
Failure code [CA271] IMV/PCV1 Short Error ...6089
Failure code [CA272] IMV/PCV1 Open Error ...6091
Failure code [CA295] Ambient Press Sens In Range Error ...6093
Failure code [CA322] Inj #1(L#1) Open/Short Error ...6094
Failure code [CA323] Inj #5(L#5) Open/Short Error ...6096
Failure code [CA324] Inj #3(L#3) Open/Short Error ...6098
Failure code [CA325] Inj #6(L#6) Open/Short Error ...6100
Failure code [CA331] Inj #2(L#2) Open/Short Error ...6102
Failure code [CA332] Inj #4(L#4) Open/Short Error ...6104
Failure code [CA343] ECM Critical Internal Failure ...6106
Failure code [CA351] Injectors Drive Circuit Error ...6107
Failure code [CA352] Sensor 1 Supply Volt Low Error ...6108
Failure code [CA356] Mass Air Flow Sensor High Error ...6110
Failure code [CA357] Mass Air Flow Sensor Low Error ...6112
Failure code [CA386] Sensor 1 Supply Volt High Error ...6114
Failure code [CA428] Water in Fuel Sensor High Error ...6115
Failure code [CA429] Water in Fuel Sensor Low Error ...6117
Failure code [CA431] Idle Validation Sw Error ...6119
Failure code [CA432] Idle Validation Process Error ...6122
Failure code [CA435] Eng Oil Press Sw Error ...6125
Failure code [CA441] Battery Voltage Low Error ...6126
Failure code [CA442] Battery Voltage High Error ...6128
Failure code [CA449] Rail Press Very High Error ...6129
Failure code [CA451] Rail Press Sensor High Error ...6130
Failure code [CA452] Rail Press Sensor Low Error ...6132
Failure code [CA488] Chg Air Temp High Torque Derate ...6134
Failure code [CA515] Rail Press Sens Sup Volt High Error ...6135
Failure code [CA516] Rail Press Sens Sup Volt Low Error ...6137
Failure code [CA553] Rail Press High Error ...6139
Failure code [CA555] Crankcase Press High Error 1 ...6140
Failure code [CA556] Crankcase Press High Error 2 ...6141
Failure code [CA559] Rail Press Low Error ...6142
Failure code [CA595] Turbo Speed High Error 2 ...6144
Failure code [CA687] Turbo Speed Low Error ...6145
Failure code [CA689] Eng Ne Speed Sensor Error ...6147
Failure code [CA691] Intake Air Temp Sens High Error ...6149
Failure code [CA692] Intake Air Temp Sens Low Error ...6151
Failure code [CA697] ECM Internal Temp Sensor High Error ...6153
Failure code [CA698] ECM Int Temp Sensor Low Error ...6154
Failure code [CA731] Eng Bkup Speed Sens Phase Error ...6155
Failure code [CA778] Eng Bkup Speed Sensor Error ...6157
Failure code [CA1117] Persistent Data Lost Error ...6162
Failure code [CA1664] KDOC Malfunction ...6163
Failure code [CA1691] Regeneration Ineffective ...6166
Failure code [CA1695] Sensor 5 Supply Volt High Error ...6169
Failure code [CA1696] Sensor 5 Supply Volt Low Error ...6170
Failure code [CA1843] Crankcase Press Sens High Error ...6172
Failure code [CA1844] Crankcase Press Sens Low Error ...6174
Failure code [CA1879] KDPF Delta P Sensor High Error ...6176
Failure code [CA1881] KDPF Delta P Sensor Low Error ...6178
Failure code [CA1883] KDPF Delta P Sens In Range Error ...6180
Failure code [CA1921] KDPF Soot Load High Error 1 ...6184
Failure code [CA1922] KDPF Soot Load High Error 2 ...6187
Failure code [CA1942] Crankcase Press Sens In Range Error ...6192
Failure code [CA1993] KDPF Delta Pressure Low Error ...6193
Failure code [CA2185] Throt Sensor Sup Volt High Error ...6196
Failure code [CA2186] Throt Sensor Sup Volt Low Error ...6198
Failure code [CA2249] Rail Press Very Low Error ...6200
Failure code [CA2271] EGR Valve Pos Sens High Error ...6201
Failure code [CA2272] EGR Valve Pos Sens Low Error ...6203
Failure code [CA2288] Turbo Speed High Error 1 ...6206
Failure code [CA2311] IMV Solenoid Error ...6207
Failure code [CA2349] EGR Valve Solenoid Open Error ...6208
Failure code [CA2353] EGR Valve Solenoid Short Error ...6210
Failure code [CA2357] EGR Valve Servo Error ...6212
Failure code [CA2373] Exhaust Manifold Press Sens High error ...6213
Failure code [CA2374] Exhaust Manifold Press Sens Low error ...6215
Failure code [CA2375] EGR Orifice Temp Sens High Error ...6217
Failure code [CA2376] EGR Orifice Temp Sens Low Error ...6219
Failure code [CA2381] KVGT Pos Sens High Error ...6221
Failure code [CA2382] KVGT Pos Sens Low Error ...6223
Failure code [CA2383] KVGT Solenoid Open Error ...6226
Failure code [CA2386] KVGT Solenoid Short Error ...6228
Failure code [CA2387] KVGT Servo Error ...6230
Failure code [CA2554] Exh Manifold Press Sens In Range Error ...6231
Failure code [CA2555] Grid Htr Relay Volt Low Error ...6232
Failure code [CA2556] Grid Htr Relay Volt High Error ...6234
Failure code [CA2637] KDOC Face Plugging ...6236
Failure code [CA2639] Manual Stationary Regeneration Request ...6238
Failure code [CA2961] EGR Orifice Temp High Error 1 ...6241
Failure code [CA2973] Chg Air Press Sensor In Range Error ...6242
Failure code [CA3133] KDPF Outlet Press Sens High Error ...6243
Failure code [CA3134] KDPF Outlet Press Sens Low Error ...6245
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ...6247
Failure code [CA3251] KDOC Inlet Temp High Error ...6251
Failure code [CA3253] KDOC Temp Error - Non Regeneration ...6254
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...6257
Failure code [CA3255] KDPF Temp Error - Non Regeneration ...6260
Failure code [CA3256] KDPF Outlet Temp High Error 1 ...6263
Failure code [CA3311] KDOC Outlet Temp High Error 2 ...6266
Failure code [CA3312] KDPF Outlet Temp High Error 2 ...6269
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...6272
Failure code [CA3314] KDOC Inlet Temp Sens High Error ...6275
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ...6278
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...6282
Failure code [CA3317] KDOC Outlet Temp Sens High Error ...6285
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...6288
Failure code [CA3319] KDPF Outlet Temp Sens High Error ...6292
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...6295
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...6298
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...6302
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...6304
Failure code [CA3741] Rail Press Valve Trip Error ...6306
Failure code [D110L4] Disconnection of Battery Relay Signal ...6307
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ...6309
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ...6311
Failure code [D191KA] Disconnection of Neutral Output Relay ...6313
Failure code [D191KB] Ground Fault of Neutral Output Relay ...6315
Failure code [D191KY] Hot Short of Neutral Output Relay ...6317
Failure code [D192KA] Disconnection of ECSS Solenoid ...6319
Failure code [D192KB] Ground Fault of ECSS Solenoid ...6321
Failure code [D192KY] Hot Short of ECSS Solenoid ...6322
Failure code [D19JKZ] Personal Code Relay Abnormality ...6323
Failure code [D1B0KA] Disconnection of HST Safety Relay ...6325
Failure code [D1B0KB] Ground Fault of HST Safety Relay ...6327
Failure code [D1B0KY] Hot Short of HST Safety Relay ...6329
Failure code [D1B0MC] Malfunction of HST Safety Relay ...6331
Failure code [D1E6KA] Disconnection of Parking Brake Relay ...6332
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ...6334
Failure code [D1E6KY] Hot Short of Parking Brake Relay ...6336
Failure code [D5ZHKA] Failure of Key SW C Signal ...6338
Failure code [D5ZHKB] Key SW C Signal Short Circuit ...6340
Failure code [D5ZHL6] Disconnection of Key SW C ...6342
Failure code [D811MC] KOMTRAX Error ...6343
Failure code [D862KA] GPS Antenna Open Circuit ...6344
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...6345
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...6347
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...6349
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ...6350
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...6352
Failure code [DAF0MB] Monitor ROM Abnormality ...6353
Failure code [DAF0MC] Monitor Error ...6354
Failure code [DAF3KK] Controller Power Source Low (MON) ...6355
Failure code [DAF8KB] Camera Power Supply Short Circuit ...6357
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ...6358
Failure code [DAFGMC] GPS Module Error ...6359
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ...6360
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ...6362
Failure code [DAFQKR] CAN2 Discon (Monitor) ...6364
Failure code [DAJ0KK] Controller Power Source Low (HST) ...6365
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ...6368
Failure code [DAJ0MC] HST Con Error ...6369
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ...6370
Failure code [DAJ2KK] Solenoid Power Source Low (HST) ...6372
Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ...6375
Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay ...6377
Failure code [DAJ5KX] Failure of 5V Power Source 0 ...6379
Failure code [DAJ6KX] Failure of 5V Power Source 1 ...6381
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) ...6383
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ...6384
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) ...6386
Failure code [DAJQKR] CAN2 Discon ( HST Con) ...6388
Failure code [DAJRKR] CAN1 Discon ( HST Con) ...6389
Failure code [DAJRMA] Inconsistency of Option Selection (HST) ...6390
Failure code [DAZ9KQ] A/C Model Selection Abnormality ...6391
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...6392
Failure code [DB2QKR] CAN2 Discon (Engine Con) ...6393
Failure code [DB2RKR] CAN1 Discon (Engine Con) ...6398
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...6402
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ...6404
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ...6406
Failure code [DDB6L4] Parking Brake Signal Malfunction ...6408
Failure code [DDD7KA] Failure of Variable Speed Control ...6411
Failure code [DDD7KY] Hot Short of Variable Speed Control ...6413
Failure code [DDK3KA] FNR SW Input Signal Disconnection ...6415
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ...6417
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...6419
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...6422
Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ...6424
Failure code [DF10KA] Disconnection of Speed Range Input ...6426
Failure code [DF10KB] Ground Fault of Speed Range Input ...6429
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ...6432
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ...6434
Failure code [DHG1KX] Out of Range of HST Oil Temp. Sensor ...6436
Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ...6438
Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) ...6440
Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ...6442
Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) ...6444
Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) ...6446
Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ...6448
Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ...6450
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. ...6452
Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ...6454
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ...6456
Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ...6458
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ...6460
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ...6462
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit ...6464
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ...6466
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit ...6468
Failure code [DHT8ZG] Steering Oil Pressure Low ...6470
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ...6471
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ...6473
Failure code [DK55KA] Failure of FNR Lever Potentio ...6475
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...6478
Failure code [DK55L5] Failure of FNR Lever Potentio ...6480
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...6481
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ...6484
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...6487
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ...6490
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ...6493
Failure code [DK70KA] Failure of inching sensor Circuit ...6496
Failure code [DK70KY] Hot Short of inching sensor Circuit ...6499
Failure code [DKA0KA] Failure of Boom Angle Sensor ...6501
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ...6503
Failure code [DKA0L0] Boom Angle Sensor Dislocation ...6505
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ...6507
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...6509
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ...6511
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ...6513
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ...6515
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ...6518
Failure code [DPQ1KR] LIN Discon (Switch Panel) ...6520
Failure code [DPQ2KR] LIN Discon (LED Unit) ...6523
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ...6526
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...6529
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...6531
Failure code [DV00KB] Ground Fault of Buzzer Output ...6533
Failure code [DW26KA] Disconnection of Motor 2 Solenoid ...6535
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ...6537
Failure code [DW26KY] Hot Short of Motor 2 Solenoid ...6539
Failure code [DW4BKA] Disconnection of Parking Brake Valve ...6541
Failure code [DW4BKB] Ground Fault of Parking Brake Valve ...6543
Failure code [DW4BKY] Hot Short of Parking Brake Valve ...6545
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...6546
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ...6548
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...6550
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ...6551
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ...6553
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ...6555
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...6556
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ...6558
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ...6560
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ...6562
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...6564
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ...6566
Failure code [DX19KA] Disconnection of Motor 1 Solenoid ...6567
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ...6569
Failure code [DX19KY] Hot Short of Motor 1 Solenoid ...6571
Failure code [DX20KA] Disconnection of Clutch Control Solenoid ...6573
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ...6575
Failure code [DX20KY] Hot Short of Clutch Control Solenoid ...6577
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. ...6579
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ...6581
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. ...6583
Failure code [DXH7KA] Disconnection of Reverse Solenoid ...6585
Failure code [DXH7KB] Ground Fault of Reverse Solenoid ...6587
Failure code [DXH7KY] Hot Short of Reverse Solenoid ...6589
Failure code [DXH8KA] Disconnection of Forward Solenoid ...6591
Failure code [DXH8KB] Ground Fault of Forward Solenoid ...6593
Failure code [DXH8KY] Hot Short of Forward Solenoid ...6595
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...6597
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ...6599
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ...6601
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...6602
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ...6604
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ...6606
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...6607
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ...6610
Failure code [J141N1] Steering Pump Over Run ...6612
Failure code [LA00L3] Failure of Fan Reverse ...6613
Failure code [M100N1] HST Pump Over Run ...6614
Failure code [M400N1] HST Motor 1 Over Run ...6615
Troubleshooting of electrical system (E-mode) ...6616
E-1 Engine does not start ...6616
E-2 Manual preheating system does not work ...6623
E-3 Automatic preheating system does not work ...6626
E-4 While preheating is working, preheating monitor does not light up ...6628
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ...6630
E-6 LCD unit on machine monitor displays nothing ...6633
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ...6635
E-8 LCD on machine monitor does not display properly ...6637
E-9 Meter unit display on machine monitor is abnormal ...6639
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...6642
E-11 Caution LED on machine monitor is abnormal ...6645
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...6647
E-13 Two switches operation of switch panel on machine monitor does not function ...6649
E-14 Switch panel buzzer of machine monitor is abnormal ...6652
E-15 Rearview monitor does not light up or backlight flickers ...6654
E-16 Rearview monitor images are not displayed clearly ...6657
E-17 Rearview monitor brightness cannot be adjusted ...6660
E-18 Night lighting lamp of rearview monitor is abnormal ...6663
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ...6665
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ...6666
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ...6670
E-22 The HST oil filter clogging caution lamp does not light up ...6672
E-23 Radiator coolant level caution lamp does not light ...6674
E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light ...6676
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 ...6677
E-26 Fuel level gauge does not indicate correct level ...6679
E-27 Seat belt caution lamp indication is abnormal ...6681
E-28 Horn does not sound ...6682
E-29 Horn does not stop sounding ...6685
E-30 Alarm buzzer does not sound ...6687
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ...6689
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 ...6690
E-33 Setting does not change while operating traction control switch ...6692
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 ...6694
E-35 Remote positioner does not work or cannot be released ...6697
E-36 Bucket positioner does not work or cannot be released ...6699
E-37 Direction selector (FNR) switch mode is not selected or not released ...6702
E-38 PZ auto tilt-in does not work ...6704
E-39 Tracktion level does not display MAX when max traction switch is turned ON ...6707
E-40 ECSS function cannot be selected or cannot be released ...6709
E-41 None of headlamp, clearance lamp, and tail lamp lights ...6711
E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out ...6713
E-43 Both High and Low beams of headlamp do not light up or go out ...6717
E-44 Low beam of headlamp does not light up or go out ...6721
E-45 High beam of headlamp does not light up or go out ...6723
E-46 Front working lamp does not light up or go out ...6725
E-47 Rear working lamp does not light up or go out ...6729
E-48 All of turn signal lamps and hazard lamps do not flash or go out ...6733
E-49 Turn signal lamps do not flash or go out ...6736
E-50 Hazard lamp does not flash or go out ...6739
E-51 Brake lamp does not light or stays lighted ...6742
E-52 Backup lamp does not light up or does not go out ...6745
E-53 Backup buzzer does not sound or continues to sound ...6748
E-54 Front wiper does not operate ...6750
E-55 Rear wiper does not operate ...6753
E-56 Window washer does not operate ...6755
E-57 KOMTRAX system does not operate normally ...6758
Troubleshooting of hydraulic and mechanical system (H-mode) ...6760
Information described in troubleshooting table (H-mode) ...6760
System chart of hydraulic and mechanical systems ...6761
Failure mode and cause table ...6763
H-1 Machine does not travel forward or backward ...6770
H-2 Machine does not travel forward (Machine travels backward normally) ...6773
H-3 Machine does not travel backward (Machine travels forward normally) ...6774
H-4 Machine does not travel forward or backward fast ...6775
H-5 Machine does not travel forward fast (Machine travel backward fast) ...6779
H-6 Machine does not travel backward fast (Machine travel forward fast) ...6780
H-7 Machine lacks power neither when traveling forward nor backward ...6781
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ...6784
H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ...6785
H-10 Engine stalls during travel or engine speed drops significantly ...6786
H-11 Steering wheel is too heavy to turn ...6787
H-12 Steering wheel is heavy to turn ...6789
H-13 Machine sways or large shocks are made while machine turns ...6790
H-14 Machine unintentionally turns when machine travels ...6791
H-15 Wheel brakes do not work or are weak ...6792
H-16 Wheel brakes are not released or drag ...6793
H-17 Parking brake does not work or it is weak ...6794
H-18 Parking brake is not released or drags. ...6795
H-19 Boom does not rise ...6796
H-20 Boom moves slow or boom lacks lifting force ...6798
H-21 Rising boom slows down at certain height ...6800
H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground). ...6801
H-23 Hydraulic drift of boom is large ...6802
H-24 Boom moves up and down during operation ...6803
H-25 Bucket does not tilt back ...6804
H-26 Bucket moves slow or lacks tilt-back force ...6806
H-27 Bucket decelerates during tilt-back operation ...6808
H-28 Bucket cylinder does not hold bucket on ground ...6809
H-29 Hydraulic drift of bucket is large ...6810
H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ...6811
H-31 Boom and bucket control levers do not move smoothly and are heavy to move ...6812
H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ...6813
H-33 Large shocks are made when work equipment starts to move and stops ...6814
H-34 When certain work equipment is relieved hydraulically, other work equipment moves ...6815
H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ...6816
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) ...6817
H-37 Unusual noise is heard from around fan ...6819
Troubleshooting of engine (S-mode) ...6820
Information described in troubleshooting table (S mode) ...6820
S-1 Engine does not crank when starting switch is turned to START position ...6821
S-2 Engine cranks but no exhaust smoke comes out ...6822
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ...6823
S-4 Engine startability is poor ...6824
S-5 Engine does not pick up smoothly ...6826
S-6 Engine stops during operation ...6828
S-7 Engine runs rough or is unstable ...6830
S-8 Engine lacks power ...6831
S-9 KDPF gets clogged in a short time ...6833
S-10 Engine oil consumption is excessive ...6835
S-11 Engine oil becomes contaminated early ...6836
S-12 Fuel consumption is excessive ...6837
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...6838
S-14 Oil pressure drops ...6839
S-15 Fuel mixes into engine oil ...6840
S-16 Water mixes into engine oil (milky) ...6841
S-17 Coolant temperature rises too high (overheating) ...6842
S-18 Unusual noise is heard ...6843
S-19 Vibration is excessive ...6844
S-20 Air cannot be bled from fuel circuit ...6846
S-21 Active regeneration is executed frequently ...6847
S-22 Active regeneration takes time ...6848
S-23 White smoke is exhausted during active regeneration ...6849
50 Disassembly and assembly ...6850
Table of contents ...6851
Related information on disassembly and assembly ...6853
How to read this manual ...6853
Coating materials list ...6855
Special tools list ...6859
Sketches of special tools ...6866
Engine and cooling system ...6882
Removal and installation of supply pump assembly ...6882
Removal and installation of injector assembly ...6886
Removal and installation of cylinder head assembly ...6895
Removal and installation of engine hood assembly ...6902
Removal and installation of grille assembly ...6905
Removal and installation of radiator core assembly ...6907
Removal and installation of aftercooler ...6910
Removal and installation of hydraulic oil cooler ...6912
Removal and installation of engine assembly ...6913
Removal and installation of engine front oil seal ...6919
Removal and installation of engine rear oil seal ...6922
Removal and installation of cooling fan and fan motor assembly ...6925
Removal and installation of KDPF assembly ...6927
Disassembly and assembly of KDPF assembly ...6931
Removal and installation of KCCV assembly ...6940
Removal and installation of air cleaner assembly ...6941
Removal and installation of KVGT assembly ...6943
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ...6947
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ...6949
Removal and installation of alternator belt ...6952
Removal and installation of fuel tank assembly ...6954
Power train ...6957
Removal and installation of transfer assembly ...6957
Disassembly and assembly of transfer assembly ...6962
Disassembly and assembly of parking brake assembly ...6994
Disassembly and assembly of differential assembly ...7002
Removal and installation of front axle assembly ...7026
Removal and installation of rear axle assembly ...7028
Disassembly and assembly of axle housing assembly ...7031
Undercarriage and frame ...7040
Removal and installation of center hinge pin ...7040
Removal and installation of counterweight assembly ...7049
Hydraulic system ...7051
Removal and installation of hydraulic tank assembly ...7051
Removal and installation of control valve assembly ...7054
Disassembly and assembly of control valve assembly ...7058
Removal and installation of hydraulic pump assembly ...7061
Removal and installation of HST motor1 assembly ...7065
Removal and installation of HST motor2 assembly ...7067
Disassembly and assembly of hydraulic cylinder assembly ...7069
Work equipment ...7076
Removal and installation of work equipment assembly ...7076
Cab and its attachments ...7082
Removal and installation of operator's cab and floor frame assembly ...7082
Removal and installation of operator's cab glass (adhered glass) ...7087
Removal and installation of operator's seat assembly ...7095
Removal and installation of seat belt ...7097
Electrical system ...7098
Removal and installation of machine monitor assembly ...7098
Removal and installation of engine controller assembly ...7100
Removal and installation of HST controller assembly ...7102
Removal and installation of air conditioner controller assembly ...7104
Removal and installation of monitor controller assembly ...7105
Removal and installation of mass air flow and temperature sensor ...7107
Removal and installation of KOMTRAX terminal assembly ...7108
Air conditioner unit ...7109
Removal and installation of air conditioner compressor ...7109
Removal and installation of air conditioner condenser ...7111
Removal and installation of air conditioner unit assembly ...7113
60 Maintenance standard ...7118
Table of contents ...7119
Engine and cooling system ...7120
Engine related parts ...7120
Cooling fan motor ...7121
Power train ...7123
Damper ...7123
Transfer ...7124
Drive shaft ...7131
Axle ...7132
Differential ...7134
Limited slip differential ...7138
Final drive ...7140
Steering system ...7144
Steering column ...7144
Priority valve ...7145
Emergency steering valve ...7146
Steering cylinder ...7147
Brake system ...7149
Brake accumulator charge valve ...7149
Slack adjuster ...7150
Brake ...7151
Parking brake ...7153
Parking brake solenoid valve ...7154
Undercarriage and frame ...7155
Axle mount ...7155
Center hinge pin ...7157
Hydraulic system ...7161
Hydraulic tank ...7161
Double type gear pump ...7162
Steering and work equipment pump ...7163
Control valve ...7167
Self-pressure reducing valve ...7180
Work equipment PPC valve ...7182
Work equipment lock solenoid valve ...7184
Work equipment ...7185
Work equipment linkage ...7185
Bucket ...7189
Work equipment cylinder ...7191
Cab and its attachments ...7192
Cab mount ...7192
Electrical system ...7193
Bucket positioner ...7193
Fork positioner ...7194
Remote boom positioner ...7195
80 Appendix ...7196
Table of contents ...7197
Air conditioner components ...7198
Precautions for refrigerant ...7198
Air conditioner component ...7199
Configuration and function of refrigeration cycle ...7201
Outline of refrigeration cycle ...7202
Air conditioner unit ...7204
Dual pressure switch ...7209
Air conditioner controller ...7210
Compressor ...7211
Condenser ...7212
Receiver drier ...7213
Sunlight sensor ...7215
Outer temperature sensor (outside air temperature sensor) ...7216
Procedure for testing and troubleshooting ...7217
Circuit diagram and arrangement of connector pins ...7219
System diagram ...7222
Parts and connectors layout ...7225
Testing with self-diagnosis function ...7230
How to open the electrical system abnormality record screen in service mode of the machine monitor ...7231
Testing temperature control system ...7233
Testing vent (mode) changeover ...7235
Testing FRESH/RECIRC air changeover ...7237
Testing evaporator temperature sensor ...7239
Testing relays ...7241
Troubleshooting chart 1 ...7243
Troubleshooting chart 2 ...7244
Information in troubleshooting table ...7246
Failure code list related to air conditioner ...7247
Failure code [879AKA] A/C Inner Sensor Open Circuit ...7248
Failure code [879AKB] A/C Inner Sensor Short Circuit ...7250
Failure code [879BKA] A/C Outer Sensor Open Circuit ...7252
Failure code [879BKB] A/C Outer Sensor Short Circuit ...7254
Failure code [879CKA] Ventilating Sensor Open Circuit ...7256
Failure code [879CKB] Ventilating Sensor Short Circuit ...7258
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...7260
Failure code [879EMC] Ventilation Damper Abnormality ...7262
Failure code [879FMC] Air Mix Damper Abnormality ...7265
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ...7268
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...7271
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...7274
A-4 Troubleshooting for FRESH/RECIRC air changeover ...7277
Troubleshooting with gauge pressure ...7279
Connection of service tool ...7282
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ...7284
Handling of compressor oil ...7286
90 Diagrams and drawings ...7288
Table of contents ...7289
Hydraulic circuit diagram ...7290
Symbols in hydraulic circuit diagram ...7290
Hydraulic circuit diagram ...7294
Electric circuit diagram ...7295
Symbols in electric circuit diagram ...7295
Electrical circuit diagram of machine body ...7299
Electrical circuit diagram of floor ...7303
INDEX...7311
SEN06255-02 - Wheel Loader WA270-7 Shop Manual...7323
00 Index and foreword ...7325
Index ...7326
Foreword, safety and general information ...7341
Important safety notice ...7341
How to read the shop manual ...7348
Explanation of terms for maintenance standard ...7350
Handling equipment of fuel system devices ...7352
Handling of intake system parts ...7353
Handling of hydraulic equipment ...7354
Method of disconnecting and connecting of push-pull type coupler ...7356
Handling of electrical equipment ...7359
How to read electric wire code ...7367
Precautions when performing operation ...7370
Practical use of KOMTRAX ...7375
Standard tightening torque table ...7376
List of abbreviation ...7382
Conversion table ...7387
01 Specification ...7393
Table of contents ...7394
Specifications ...7395
Specification drawing ...7395
Specifications ...7399
Weight table ...7409
Table of fuel, coolant, and lubricants ...7413
10 Structure and function ...7415
Table of contents ...7416
Engine and cooling system ...7418
Engine related parts ...7418
KVGT ...7420
EGR system piping drawing ...7427
EGR system circuit diagram ...7429
EGR valve ...7431
EGR cooler ...7433
KCCV layout drawing ...7434
KCCV ventilator ...7436
KDPF ...7438
Cooling system ...7442
Cooling fan motor ...7444
Power train ...7454
Power train system ...7454
Layout of power train parts ...7456
Damper ...7457
HST pump ...7458
HST motor1 ...7471
HST motor2 ...7473
Transfer ...7478
Clutch solenoid valve ...7485
Drive shaft ...7487
Axle ...7488
Differential ...7490
Torque proportional differential ...7494
Limited slip differential ...7496
Final drive ...7501
Steering system ...7504
Layout of steering devices ...7504
Steering column ...7505
Priority valve ...7506
Cushion valve ...7510
Emergency steering valve ...7511
Orbitrol valve ...7514
2way restrictor valve ...7520
Brake system ...7521
Layout of brake parts ...7521
Brake accumulator charge valve ...7523
Brake valve ...7528
Brake accumulator ...7532
Slack adjuster ...7533
Brake ...7535
Parking brake control ...7538
Parking brake ...7539
Parking brake solenoid valve ...7540
Undercarriage and frame ...7542
Axle mount ...7542
Center hinge pin ...7544
Tire ...7545
Hydraulic system ...7547
Hydraulic component layout ...7547
Work equipment control ...7549
Hydraulic tank ...7550
Double type gear pump ...7553
Steering and work equipment pump ...7554
Control valve ...7566
CLSS ...7576
Hydraulic circuit diagram and names of valves ...7580
Self-pressure reducing valve ...7593
Work equipment PPC valve ...7598
Work equipment lock solenoid valve ...7606
PPC circuit accumulator ...7607
ECSS accumulator ...7608
Work equipment ...7609
Work equipment linkage ...7609
Bucket ...7610
Cab and its attachments ...7611
ROPS cab ...7611
Cab mount ...7613
Electrical system ...7614
Engine control system ...7614
Preheating system ...7617
Engine output limit function ...7619
Automatic warm-up function ...7620
Parking brake control system ...7621
System operating lamp function ...7625
Battery disconnect switch function ...7626
HST controller system ...7628
Machine monitor system ...7668
Rearview monitor system ...7689
KOMTRAX system ...7692
System component parts ...7695
Sensor ...7718
20 Standard value tables ...7739
Table of contents ...7740
Standard service value table ...7741
Standard value table for engine ...7741
Standard value table for machine ...7743
Standard value table for electrical system ...7755
30 Testing and adjusting ...7765
Table of contents ...7766
Related information on testing and adjusting ...7768
Tools for testing and adjusting ...7768
Sketch of tools for testing and adjusting ...7774
Engine and cooling system ...7775
Testing engine speed ...7775
Testing boost pressure ...7776
Testing exhaust gas temperature ...7778
Testing exhaust gas color ...7779
Testing and adjusting valve clearance ...7781
Testing compression pressure ...7783
Testing blowby pressure ...7787
Testing engine oil pressure ...7788
Testing EGR valve and KVGT driving oil pressure ...7789
Testing fuel pressure ...7790
Testing fuel discharge, return and leakage ...7794
Bleeding air from fuel system ...7799
Testing fuel circuit for leakage ...7801
Handling cylinder cutout mode operation ...7802
Handling no-injection cranking operation ...7803
Testing of KDPF and muffler stack for looseness and damage ...7804
Testing of installed condition of cylinder heads and manifolds ...7805
Testing engine piping for damage and looseness ...7806
Testing and adjusting air conditioner compressor belt tension ...7807
Replacing alternator belt ...7808
Power train ...7809
Testing oil leakage from axle final drive ...7809
Testing drive shaft for looseness, backlash, and damage ...7810
Testing accelerator pedal ...7811
Testing and adjusting HST oil pressure ...7812
Testing transfer clutch control pressure ...7815
Steering system ...7816
Testing directional lever ...7816
Testing steering wheel ...7817
Testing work equipment control lever ...7819
Testing and adjusting steering circuit oil pressure ...7821
Bleeding air from steering cylinder circuit ...7823
Brake system ...7824
Testing brake pedal ...7824
Testing braking performance ...7825
Testing and adjusting of accumulator charge pressure ...7826
Testing wheel brake oil pressure ...7828
Testing lowering of wheel brake pressure ...7829
Testing wear of wheel brake disc ...7831
Bleeding air from wheel brake circuit ...7832
Releasing remaining pressure in brake accumulator circuit ...7833
Testing parking brake performance ...7834
Testing wear of parking brake disc ...7835
Testing parking brake release pressure ...7836
Method of releasing parking brake manually ...7837
Hydraulic system ...7838
Testing cooling fan speed ...7838
Testing cooling fan pump circuit oil pressure ...7839
Bleeding air from hydraulic fan circuit ...7841
Testing and adjusting work equipment PPC oil pressure ...7842
Testing and adjusting work equipment oil pressure ...7844
Bleeding air from work equipment circuit ...7848
Releasing remaining pressure from work equipment circuit ...7849
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ...7851
Work equipment ...7855
Testing and adjusting bucket positioner and bucket proximity switch ...7855
Testing and adjusting boom position detection lever ...7857
Electrical system ...7858
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...7858
Special functions of machine monitor ...7859
Adjusting rearview camera angle ...7937
Handling voltage circuit of engine controller ...7938
Handling battery disconnect switch ...7939
Testing diodes ...7940
Pm clinic ...7941
Pm Clinic service ...7941
Check sheet ...7942
40 Troubleshooting ...7947
Table of contents ...7948
Related information on troubleshooting ...7957
Troubleshooting points ...7957
Sequence of events in troubleshooting ...7959
Checks before troubleshooting ...7961
Inspection procedure before troubleshooting ...7963
Preparation for troubleshooting of electrical system ...7980
Classification and procedures for troubleshooting ...7986
Symptom and troubleshooting numbers ...7989
Information described in troubleshooting table ...7992
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ...7994
Connector list and layout ...7997
Connector contact identification ...8011
T-branch box and T-branch adapter table ...8049
Fuse location table ...8054
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ...8057
Precautions when performing troubleshooting of machine monitor ...8060
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ...8062
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ...8067
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ...8068
Failure codes table ...8069
Troubleshooting by failure code (Display of code) ...8081
Failure code [2F00MA] Failure of Parking Brake Circuit ...8081
Failure code [2F00MB] Malfunction of Parking Brake ...8084
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...8086
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ...8088
Failure code [6091NX] HST Oil Filter Clogging ...8090
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ...8092
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol. ...8094
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ...8096
Failure code [879AKA] A/C Inner Sensor Open Circuit ...8098
Failure code [879AKB] A/C Inner Sensor Short Circuit ...8099
Failure code [879BKA] A/C Outer Sensor Open Circuit ...8100
Failure code [879BKB] A/C Outer Sensor Short Circuit ...8101
Failure code [879CKA] Ventilating Sensor Open Circuit ...8102
Failure code [879CKB] Ventilating Sensor Short Circuit ...8103
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...8104
Failure code [879EMC] Ventilation Damper Abnormality ...8105
Failure code [879FMC] Air Mix Damper Abnormality ...8106
Failure code [989L00] Engine Controller Lock Caution 1 ...8107
Failure code [989M00] Engine Controller Lock Caution 2 ...8108
Failure code [989N00] Engine Controller Lock Caution 3 ...8109
Failure code [A1U0N3] HC Desorb Request 1 ...8110
Failure code [A1U0N4] HC Desorb Request 2 ...8112
Failure code [B@BAZG] Eng Oil Press Low ...8114
Failure code [B@BCNS] Eng Water Overheat ...8115
Failure code [B@BCZK] Eng Water Level Low ...8116
Failure code [B@CRNS] HST Oil Temp. Overheat ...8118
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ...8119
Failure code [CA122] Chg Air Press Sensor High Error ...8120
Failure code [CA123] Chg Air Press Sensor Low Error ...8122
Failure code [CA131] Throttle Sensor High Error ...8124
Failure code [CA132] Throttle Sensor Low Error ...8126
Failure code [CA144] Coolant Temp Sens High Error ...8128
Failure code [CA145] Coolant Temp Sens Low Error ...8130
Failure code [CA153] Chg Air Temp Sensor High Error ...8132
Failure code [CA154] Chg Air Temp Sensor Low Error ...8134
Failure code [CA187] Sensor 2 Supply Volt Low Error ...8136
Failure code [CA221] Ambient Press Sensor High Error ...8138
Failure code [CA222] Ambient Press Sensor Low Error ...8140
Failure code [CA227] Sensor 2 Supply Volt High Error ...8142
Failure code [CA234] Eng Overspeed ...8143
Failure code [CA238] Ne Speed Sensor Supply Volt Error ...8144
Failure code [CA239] Ne Speed Sens Supply Volt High Error ...8145
Failure code [CA271] IMV/PCV1 Short Error ...8146
Failure code [CA272] IMV/PCV1 Open Error ...8148
Failure code [CA295] Ambient Press Sens In Range Error ...8150
Failure code [CA322] Inj #1(L#1) Open/Short Error ...8151
Failure code [CA323] Inj #5(L#5) Open/Short Error ...8153
Failure code [CA324] Inj #3(L#3) Open/Short Error ...8155
Failure code [CA325] Inj #6(L#6) Open/Short Error ...8157
Failure code [CA331] Inj #2(L#2) Open/Short Error ...8159
Failure code [CA332] Inj #4(L#4) Open/Short Error ...8161
Failure code [CA343] ECM Critical Internal Failure ...8163
Failure code [CA351] Injectors Drive Circuit Error ...8164
Failure code [CA352] Sensor 1 Supply Volt Low Error ...8165
Failure code [CA356] Mass Air Flow Sensor High Error ...8167
Failure code [CA357] Mass Air Flow Sensor Low Error ...8169
Failure code [CA386] Sensor 1 Supply Volt High Error ...8171
Failure code [CA428] Water in Fuel Sensor High Error ...8172
Failure code [CA429] Water in Fuel Sensor Low Error ...8174
Failure code [CA431] Idle Validation Sw Error ...8176
Failure code [CA432] Idle Validation Process Error ...8179
Failure code [CA435] Eng Oil Press Sw Error ...8182
Failure code [CA441] Battery Voltage Low Error ...8183
Failure code [CA442] Battery Voltage High Error ...8185
Failure code [CA449] Rail Press Very High Error ...8186
Failure code [CA451] Rail Press Sensor High Error ...8187
Failure code [CA452] Rail Press Sensor Low Error ...8189
Failure code [CA488] Chg Air Temp High Torque Derate ...8191
Failure code [CA515] Rail Press Sens Sup Volt High Error ...8192
Failure code [CA516] Rail Press Sens Sup Volt Low Error ...8194
Failure code [CA553] Rail Press High Error ...8196
Failure code [CA555] Crankcase Press High Error 1 ...8197
Failure code [CA556] Crankcase Press High Error 2 ...8198
Failure code [CA559] Rail Press Low Error ...8199
Failure code [CA595] Turbo Speed High Error 2 ...8201
Failure code [CA687] Turbo Speed Low Error ...8202
Failure code [CA689] Eng Ne Speed Sensor Error ...8204
Failure code [CA691] Intake Air Temp Sens High Error ...8206
Failure code [CA692] Intake Air Temp Sens Low Error ...8208
Failure code [CA697] ECM Internal Temp Sensor High Error ...8210
Failure code [CA698] ECM Int Temp Sensor Low Error ...8211
Failure code [CA731] Eng Bkup Speed Sens Phase Error ...8212
Failure code [CA778] Eng Bkup Speed Sensor Error ...8214
Failure code [CA1117] Persistent Data Lost Error ...8219
Failure code [CA1664] KDOC Malfunction ...8220
Failure code [CA1691] Regeneration Ineffective ...8223
Failure code [CA1695] Sensor 5 Supply Volt High Error ...8226
Failure code [CA1696] Sensor 5 Supply Volt Low Error ...8227
Failure code [CA1843] Crankcase Press Sens High Error ...8229
Failure code [CA1844] Crankcase Press Sens Low Error ...8231
Failure code [CA1879] KDPF Delta P Sensor High Error ...8233
Failure code [CA1881] KDPF Delta P Sensor Low Error ...8235
Failure code [CA1883] KDPF Delta P Sens In Range Error ...8237
Failure code [CA1921] KDPF Soot Load High Error 1 ...8241
Failure code [CA1922] KDPF Soot Load High Error 2 ...8244
Failure code [CA1942] Crankcase Press Sens In Range Error ...8249
Failure code [CA1993] KDPF Delta Pressure Low Error ...8250
Failure code [CA2185] Throt Sensor Sup Volt High Error ...8253
Failure code [CA2186] Throt Sensor Sup Volt Low Error ...8255
Failure code [CA2249] Rail Press Very Low Error ...8257
Failure code [CA2271] EGR Valve Pos Sens High Error ...8258
Failure code [CA2272] EGR Valve Pos Sens Low Error ...8260
Failure code [CA2288] Turbo Speed High Error 1 ...8263
Failure code [CA2311] IMV Solenoid Error ...8264
Failure code [CA2349] EGR Valve Solenoid Open Error ...8265
Failure code [CA2353] EGR Valve Solenoid Short Error ...8267
Failure code [CA2357] EGR Valve Servo Error ...8269
Failure code [CA2373] Exhaust Manifold Press Sens High error ...8270
Failure code [CA2374] Exhaust Manifold Press Sens Low error ...8272
Failure code [CA2375] EGR Orifice Temp Sens High Error ...8274
Failure code [CA2376] EGR Orifice Temp Sens Low Error ...8276
Failure code [CA2381] KVGT Pos Sens High Error ...8278
Failure code [CA2382] KVGT Pos Sens Low Error ...8280
Failure code [CA2383] KVGT Solenoid Open Error ...8283
Failure code [CA2386] KVGT Solenoid Short Error ...8285
Failure code [CA2387] KVGT Servo Error ...8287
Failure code [CA2554] Exh Manifold Press Sens In Range Error ...8288
Failure code [CA2555] Grid Htr Relay Volt Low Error ...8289
Failure code [CA2556] Grid Htr Relay Volt High Error ...8291
Failure code [CA2637] KDOC Face Plugging ...8293
Failure code [CA2639] Manual Stationary Regeneration Request ...8295
Failure code [CA2961] EGR Orifice Temp High Error 1 ...8298
Failure code [CA2973] Chg Air Press Sensor In Range Error ...8299
Failure code [CA3133] KDPF Outlet Press Sens High Error ...8300
Failure code [CA3134] KDPF Outlet Press Sens Low Error ...8302
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ...8304
Failure code [CA3251] KDOC Inlet Temp High Error ...8308
Failure code [CA3253] KDOC Temp Error - Non Regeneration ...8311
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...8314
Failure code [CA3255] KDPF Temp Error - Non Regeneration ...8317
Failure code [CA3256] KDPF Outlet Temp High Error 1 ...8320
Failure code [CA3311] KDOC Outlet Temp High Error 2 ...8323
Failure code [CA3312] KDPF Outlet Temp High Error 2 ...8326
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...8329
Failure code [CA3314] KDOC Inlet Temp Sens High Error ...8332
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ...8335
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...8339
Failure code [CA3317] KDOC Outlet Temp Sens High Error ...8342
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...8345
Failure code [CA3319] KDPF Outlet Temp Sens High Error ...8349
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...8352
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...8355
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...8359
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...8361
Failure code [CA3741] Rail Press Valve Trip Error ...8363
Failure code [D110L4] Disconnection of Battery Relay Signal ...8364
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ...8366
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ...8368
Failure code [D191KA] Disconnection of Neutral Output Relay ...8370
Failure code [D191KB] Ground Fault of Neutral Output Relay ...8372
Failure code [D191KY] Hot Short of Neutral Output Relay ...8374
Failure code [D192KA] Disconnection of ECSS Solenoid ...8376
Failure code [D192KB] Ground Fault of ECSS Solenoid ...8378
Failure code [D192KY] Hot Short of ECSS Solenoid ...8379
Failure code [D19JKZ] Personal Code Relay Abnormality ...8380
Failure code [D1B0KA] Disconnection of HST Safety Relay ...8382
Failure code [D1B0KB] Ground Fault of HST Safety Relay ...8384
Failure code [D1B0KY] Hot Short of HST Safety Relay ...8386
Failure code [D1B0MC] Malfunction of HST Safety Relay ...8388
Failure code [D1E6KA] Disconnection of Parking Brake Relay ...8389
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ...8391
Failure code [D1E6KY] Hot Short of Parking Brake Relay ...8393
Failure code [D5ZHKA] Failure of Key SW C Signal ...8395
Failure code [D5ZHKB] Key SW C Signal Short Circuit ...8397
Failure code [D5ZHL6] Disconnection of Key SW C ...8399
Failure code [D811MC] KOMTRAX Error ...8400
Failure code [D862KA] GPS Antenna Open Circuit ...8401
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...8402
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...8404
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...8406
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ...8407
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...8409
Failure code [DAF0MB] Monitor ROM Abnormality ...8410
Failure code [DAF0MC] Monitor Error ...8411
Failure code [DAF3KK] Controller Power Source Low (MON) ...8412
Failure code [DAF8KB] Camera Power Supply Short Circuit ...8414
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ...8415
Failure code [DAFGMC] GPS Module Error ...8416
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ...8417
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ...8419
Failure code [DAFQKR] CAN2 Discon (Monitor) ...8421
Failure code [DAJ0KK] Controller Power Source Low (HST) ...8422
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) ...8425
Failure code [DAJ0MC] HST Con Error ...8426
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ...8427
Failure code [DAJ2KK] Solenoid Power Source Low (HST) ...8429
Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ...8432
Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay ...8434
Failure code [DAJ5KX] Failure of 5V Power Source 0 ...8436
Failure code [DAJ6KX] Failure of 5V Power Source 1 ...8438
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) ...8440
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ...8441
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) ...8443
Failure code [DAJQKR] CAN2 Discon ( HST Con) ...8445
Failure code [DAJRKR] CAN1 Discon ( HST Con) ...8446
Failure code [DAJRMA] Inconsistency of Option Selection (HST) ...8447
Failure code [DAZ9KQ] A/C Model Selection Abnormality ...8448
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...8449
Failure code [DB2QKR] CAN2 Discon (Engine Con) ...8450
Failure code [DB2RKR] CAN1 Discon (Engine Con) ...8455
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...8459
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ...8461
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction ...8463
Failure code [DDB6L4] Parking Brake Signal Malfunction ...8465
Failure code [DDD7KA] Failure of Variable Speed Control ...8468
Failure code [DDD7KY] Hot Short of Variable Speed Control ...8470
Failure code [DDK3KA] FNR SW Input Signal Disconnection ...8472
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ...8474
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...8476
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...8479
Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ...8481
Failure code [DF10KA] Disconnection of Speed Range Input ...8483
Failure code [DF10KB] Ground Fault of Speed Range Input ...8486
Failure code [DGH1KX] Out of Range of HST Oil Temp. Sensor ...8489
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ...8491
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ...8493
Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ...8495
Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) ...8497
Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ...8499
Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) ...8501
Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) ...8503
Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ...8505
Failure code [DHPEKA] Failure of Steering & Loader Pump Press. ...8507
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press. ...8509
Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ...8511
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit ...8513
Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ...8515
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit ...8517
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit ...8519
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit ...8521
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit ...8523
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit ...8525
Failure code [DHT8ZG] Steering Oil Pressure Low ...8527
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ...8528
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ...8530
Failure code [DK55KA] Failure of FNR Lever Potentio ...8532
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...8535
Failure code [DK55L5] Failure of FNR Lever Potentio ...8537
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...8538
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ...8541
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...8544
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ...8547
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ...8550
Failure code [DK70KA] Failure of inching sensor Circuit ...8553
Failure code [DK70KY] Hot Short of inching sensor Circuit ...8556
Failure code [DKA0KA] Failure of Boom Angle Sensor ...8558
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ...8560
Failure code [DKA0L0] Boom Angle Sensor Dislocation ...8562
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ...8564
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...8566
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) ...8568
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) ...8570
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) ...8572
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ...8575
Failure code [DPQ1KR] LIN Discon (Switch Panel) ...8577
Failure code [DPQ2KR] LIN Discon (LED Unit) ...8580
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ...8583
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...8586
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...8588
Failure code [DV00KB] Ground Fault of Buzzer Output ...8590
Failure code [DW26KA] Disconnection of Motor 2 Solenoid ...8592
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ...8594
Failure code [DW26KY] Hot Short of Motor 2 Solenoid ...8596
Failure code [DW4BKA] Disconnection of Parking Brake Valve ...8598
Failure code [DW4BKB] Ground Fault of Parking Brake Valve ...8600
Failure code [DW4BKY] Hot Short of Parking Brake Valve ...8602
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...8603
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ...8605
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...8607
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ...8608
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ...8610
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ...8612
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...8613
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ...8615
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ...8617
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ...8619
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...8621
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ...8623
Failure code [DX19KA] Disconnection of Motor 1 Solenoid ...8624
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid ...8626
Failure code [DX19KY] Hot Short of Motor 1 Solenoid ...8628
Failure code [DX20KA] Disconnection of Clutch Control Solenoid ...8630
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid ...8632
Failure code [DX20KY] Hot Short of Clutch Control Solenoid ...8634
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. ...8636
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol. ...8638
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. ...8640
Failure code [DXH7KA] Disconnection of Reverse Solenoid ...8642
Failure code [DXH7KB] Ground Fault of Reverse Solenoid ...8644
Failure code [DXH7KY] Hot Short of Reverse Solenoid ...8646
Failure code [DXH8KA] Disconnection of Forward Solenoid ...8648
Failure code [DXH8KB] Ground Fault of Forward Solenoid ...8650
Failure code [DXH8KY] Hot Short of Forward Solenoid ...8652
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...8654
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ...8656
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ...8658
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...8659
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ...8661
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ...8663
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...8664
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ...8667
Failure code [J141N1] Steering Pump Over Run ...8669
Failure code [LA00L3] Failure of Fan Reverse ...8670
Failure code [M100N1] HST Pump Over Run ...8671
Failure code [M400N1] HST Motor 1 Over Run ...8672
Troubleshooting of electrical system (E-mode) ...8673
E-1 Engine does not start ...8673
E-2 Manual preheating system does not work ...8680
E-3 Automatic preheating system does not work ...8683
E-4 While preheating is working, preheating monitor does not light up ...8685
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ...8687
E-6 LCD unit on machine monitor displays nothing ...8690
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ...8692
E-8 LCD on machine monitor does not display properly ...8694
E-9 Meter unit display on machine monitor is abnormal ...8696
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...8699
E-11 Caution LED on machine monitor is abnormal ...8702
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...8704
E-13 Two switches operation of switch panel on machine monitor does not function ...8706
E-14 Switch panel buzzer of machine monitor is abnormal ...8709
E-15 Rearview monitor does not light up or backlight flickers ...8711
E-16 Rearview monitor images are not displayed clearly ...8714
E-17 Rearview monitor brightness cannot be adjusted ...8717
E-18 Night lighting lamp of rearview monitor is abnormal ...8720
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ...8722
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ...8723
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ...8727
E-22 The HST oil filter clogging caution lamp does not light up ...8729
E-23 Radiator coolant level caution lamp does not light ...8731
E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light ...8733
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 ...8734
E-26 Fuel level gauge does not indicate correct level ...8736
E-27 Seat belt caution lamp indication is abnormal ...8738
E-28 Horn does not sound ...8739
E-29 Horn does not stop sounding ...8742
E-30 Alarm buzzer does not sound ...8744
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ...8746
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 ...8747
E-33 Setting does not change while operating traction control switch ...8749
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 ...8751
E-35 Remote positioner does not work or cannot be released ...8754
E-36 Bucket positioner does not work or cannot be released ...8756
E-37 Direction selector (FNR) switch mode is not selected or not released ...8759
E-38 PZ auto tilt-in does not work ...8761
E-39 Tracktion level does not display MAX when max traction switch is turned ON ...8764
E-40 ECSS function cannot be selected or cannot be released ...8766
E-41 None of headlamp, clearance lamp, and tail lamp lights ...8768
E-42 Clearance lamp, tail lamp and license-plate lamp do not light up or go out ...8770
E-43 Both High and Low beams of headlamp do not light up or go out ...8774
E-44 Low beam of headlamp does not light up or go out ...8778
E-45 High beam of headlamp does not light up or go out ...8780
E-46 Front working lamp does not light up or go out ...8782
E-47 Rear working lamp does not light up or go out ...8786
E-48 All of turn signal lamps and hazard lamps do not flash or go out ...8790
E-49 Turn signal lamps do not flash or go out ...8793
E-50 Hazard lamp does not flash or go out ...8796
E-51 Brake lamp does not light or stays lighted ...8799
E-52 Backup lamp does not light up or does not go out ...8802
E-53 Backup buzzer does not sound or continues to sound ...8805
E-54 Front wiper does not operate ...8807
E-55 Rear wiper does not operate ...8810
E-56 Window washer does not operate ...8812
E-57 KOMTRAX system does not operate normally ...8815
Troubleshooting of hydraulic and mechanical system (H-mode) ...8817
Information described in troubleshooting table (H-mode) ...8817
System chart of hydraulic and mechanical systems ...8818
Failure mode and cause table ...8820
H-1 Machine does not travel forward or backward ...8827
H-2 Machine does not travel forward (Machine travels backward normally) ...8830
H-3 Machine does not travel backward (Machine travels forward normally) ...8831
H-4 Machine does not travel forward or backward fast ...8832
H-5 Machine does not travel forward fast (Machine travel backward fast) ...8836
H-6 Machine does not travel backward fast (Machine travel forward fast) ...8837
H-7 Machine lacks power neither when traveling forward nor backward ...8838
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward) ...8841
H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward) ...8842
H-10 Engine stalls during travel or engine speed drops significantly ...8843
H-11 Steering wheel is too heavy to turn ...8844
H-12 Steering wheel is heavy to turn ...8846
H-13 Machine sways or large shocks are made while machine turns ...8847
H-14 Machine unintentionally turns when machine travels ...8848
H-15 Wheel brakes do not work or are weak ...8849
H-16 Wheel brakes are not released or drag ...8850
H-17 Parking brake does not work or it is weak ...8851
H-18 Parking brake is not released or drags. ...8852
H-19 Boom does not rise ...8853
H-20 Boom moves slow or boom lacks lifting force ...8855
H-21 Rising boom slows down at certain height ...8857
H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground). ...8858
H-23 Hydraulic drift of boom is large ...8859
H-24 Boom moves up and down during operation ...8860
H-25 Bucket does not tilt back ...8861
H-26 Bucket moves slow or lacks tilt-back force ...8863
H-27 Bucket decelerates during tilt-back operation ...8865
H-28 Bucket cylinder does not hold bucket on ground ...8866
H-29 Hydraulic drift of bucket is large ...8867
H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ...8868
H-31 Boom and bucket control levers do not move smoothly and are heavy to move ...8869
H-32 Operating work equipment causes engine speed to lower significantly or engine to stall ...8870
H-33 Large shocks are made when work equipment starts to move and stops ...8871
H-34 When certain work equipment is relieved hydraulically, other work equipment moves ...8872
H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces ...8873
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) ...8874
H-37 Unusual noise is heard from around fan ...8876
Troubleshooting of engine (S-mode) ...8877
Information described in troubleshooting table (S mode) ...8877
S-1 Engine does not crank when starting switch is turned to START position ...8878
S-2 Engine cranks but no exhaust smoke comes out ...8879
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ...8880
S-4 Engine startability is poor ...8881
S-5 Engine does not pick up smoothly ...8883
S-6 Engine stops during operation ...8885
S-7 Engine runs rough or is unstable ...8887
S-8 Engine lacks power ...8888
S-9 KDPF gets clogged in a short time ...8890
S-10 Engine oil consumption is excessive ...8892
S-11 Engine oil becomes contaminated early ...8893
S-12 Fuel consumption is excessive ...8894
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...8895
S-14 Oil pressure drops ...8896
S-15 Fuel mixes into engine oil ...8897
S-16 Water mixes into engine oil (milky) ...8898
S-17 Coolant temperature rises too high (overheating) ...8899
S-18 Unusual noise is heard ...8900
S-19 Vibration is excessive ...8901
S-20 Air cannot be bled from fuel circuit ...8903
S-21 Active regeneration is executed frequently ...8904
S-22 Active regeneration takes time ...8905
S-23 White smoke is exhausted during active regeneration ...8906
50 Disassembly and assembly ...8907
Table of contents ...8908
Related information on disassembly and assembly ...8910
How to read this manual ...8910
Coating materials list ...8912
Special tools list ...8916
Sketches of special tools ...8923
Engine and cooling system ...8939
Removal and installation of supply pump assembly ...8939
Removal and installation of injector assembly ...8943
Removal and installation of cylinder head assembly ...8952
Removal and installation of engine hood assembly ...8959
Removal and installation of grille assembly ...8962
Removal and installation of radiator core assembly ...8964
Removal and installation of aftercooler ...8967
Removal and installation of hydraulic oil cooler ...8969
Removal and installation of engine assembly ...8970
Removal and installation of engine front oil seal ...8976
Removal and installation of engine rear oil seal ...8979
Removal and installation of cooling fan and fan motor assembly ...8982
Removal and installation of KDPF assembly ...8984
Disassembly and assembly of KDPF assembly ...8988
Removal and installation of KCCV assembly ...8997
Removal and installation of air cleaner assembly ...8998
Removal and installation of KVGT assembly ...9000
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ...9004
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ...9006
Removal and installation of alternator belt ...9009
Removal and installation of fuel tank assembly ...9011
Power train ...9014
Removal and installation of transfer assembly ...9014
Disassembly and assembly of transfer assembly ...9019
Disassembly and assembly of parking brake assembly ...9051
Disassembly and assembly of differential assembly ...9059
Removal and installation of front axle assembly ...9083
Removal and installation of rear axle assembly ...9085
Disassembly and assembly of axle housing assembly ...9088
Undercarriage and frame ...9097
Removal and installation of center hinge pin ...9097
Removal and installation of counterweight assembly ...9106
Hydraulic system ...9108
Removal and installation of hydraulic tank assembly ...9108
Removal and installation of control valve assembly ...9111
Disassembly and assembly of control valve assembly ...9115
Removal and installation of hydraulic pump assembly ...9118
Removal and installation of HST motor1 assembly ...9122
Removal and installation of HST motor2 assembly ...9124
Disassembly and assembly of hydraulic cylinder assembly ...9126
Work equipment ...9133
Removal and installation of work equipment assembly ...9133
Cab and its attachments ...9139
Removal and installation of operator's cab and floor frame assembly ...9139
Removal and installation of operator's cab glass (adhered glass) ...9144
Removal and installation of operator's seat assembly ...9152
Removal and installation of seat belt ...9154
Electrical system ...9155
Removal and installation of machine monitor assembly ...9155
Removal and installation of engine controller assembly ...9157
Removal and installation of HST controller assembly ...9159
Removal and installation of air conditioner controller assembly ...9161
Removal and installation of monitor controller assembly ...9162
Removal and installation of mass air flow and temperature sensor ...9164
Removal and installation of KOMTRAX terminal assembly ...9165
Air conditioner unit ...9166
Removal and installation of air conditioner compressor ...9166
Removal and installation of air conditioner condenser ...9168
Removal and installation of air conditioner unit assembly ...9170
60 Maintenance standard ...9175
Table of contents ...9176
Engine and cooling system ...9177
Engine related parts ...9177
Cooling fan motor ...9178
Power train ...9180
Damper ...9180
Transfer ...9181
Drive shaft ...9188
Axle ...9189
Differential ...9191
Limited slip differential ...9195
Final drive ...9197
Steering system ...9201
Steering column ...9201
Priority valve ...9202
Emergency steering valve ...9203
Steering cylinder ...9204
Brake system ...9206
Brake accumulator charge valve ...9206
Slack adjuster ...9207
Brake ...9208
Parking brake ...9210
Parking brake solenoid valve ...9211
Undercarriage and frame ...9212
Axle mount ...9212
Center hinge pin ...9214
Hydraulic system ...9218
Hydraulic tank ...9218
Double type gear pump ...9219
Steering and work equipment pump ...9220
Control valve ...9224
Self-pressure reducing valve ...9237
Work equipment PPC valve ...9239
Work equipment lock solenoid valve ...9241
Work equipment ...9242
Work equipment linkage ...9242
Bucket ...9246
Work equipment cylinder ...9248
Cab and its attachments ...9249
Cab mount ...9249
Electrical system ...9250
Bucket positioner ...9250
Fork positioner ...9251
Remote boom positioner ...9252
80 Appendix ...9253
Table of contents ...9254
Air conditioner components ...9255
Precautions for refrigerant ...9255
Air conditioner component ...9256
Configuration and function of refrigeration cycle ...9258
Outline of refrigeration cycle ...9259
Air conditioner unit ...9261
Dual pressure switch ...9266
Air conditioner controller ...9267
Compressor ...9268
Condenser ...9269
Receiver drier ...9270
Sunlight sensor ...9272
Outer temperature sensor (outside air temperature sensor) ...9273
Procedure for testing and troubleshooting ...9274
Circuit diagram and arrangement of connector pins ...9276
System diagram ...9279
Parts and connectors layout ...9282
Testing with self-diagnosis function ...9287
How to open the electrical system abnormality record screen in service mode of the machine monitor ...9288
Testing temperature control system ...9290
Testing vent (mode) changeover ...9292
Testing FRESH/RECIRC air changeover ...9294
Testing evaporator temperature sensor ...9296
Testing relays ...9298
Troubleshooting chart 1 ...9300
Troubleshooting chart 2 ...9301
Information in troubleshooting table ...9303
Failure code list related to air conditioner ...9304
Failure code [879AKA] A/C Inner Sensor Open Circuit ...9305
Failure code [879AKB] A/C Inner Sensor Short Circuit ...9307
Failure code [879BKA] A/C Outer Sensor Open Circuit ...9309
Failure code [879BKB] A/C Outer Sensor Short Circuit ...9311
Failure code [879CKA] Ventilating Sensor Open Circuit ...9313
Failure code [879CKB] Ventilating Sensor Short Circuit ...9315
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...9317
Failure code [879EMC] Ventilation Damper Abnormality ...9319
Failure code [879FMC] Air Mix Damper Abnormality ...9322
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ...9325
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...9328
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...9331
A-4 Troubleshooting for FRESH/RECIRC air changeover ...9334
Troubleshooting with gauge pressure ...9336
Connection of service tool ...9339
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ...9341
Handling of compressor oil ...9343
90 Diagrams and drawings ...9345
Table of contents ...9346
Hydraulic circuit diagram ...9347
Symbols in hydraulic circuit diagram ...9347
Hydraulic circuit diagram...9351
Electric circuit diagram ...9352
Symbols in electric circuit diagram ...9352
Electrical circuit diagram of machine body...9355
Electrical circuit diagram of floor...9359
INDEX...9367
TEN00617-01 - Wheel Loader WA270-7 Shop Manual...9379
COVER...9379
FOREWORD ...9380
BEFORE READING THIS MANUAL ...9381
SAFETY INFORMATION ...9382
INTRODUCTION ...9383
USE OF MACHINE ...9383
DIRECTIONS OF MACHINE ...9383
VISIBILITY FROM OPERATOR'S SEAT ...9383
PRODUCT INFORMATION ...9384
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ...9384
EPA REGULATIONS, ENGINE NUMBER PLATE ...9384
SERVICE METER LOCATION ...9385
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ...9385
CONTENTS ...9386
SAFETY ...9390
SAFETY ...9391
SAFETY LABELS ...9393
LOCATION OF SAFETY LABELS ...9393
SAFETY LABELS ...9394
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ...9401
PRECAUTIONS BEFORE STARTING OPERATION ...9401
PREPARATIONS FOR SAFE OPERATION ...9402
FIRE PREVENTION ...9404
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ...9406
DO NOT GET CAUGHT IN WORK EQUIPMENT ...9409
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ...9409
UNAUTHORIZED MODIFICATION ...9409
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ...9410
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ...9410
PRECAUTIONS FOR OPERATION ...9411
PRECAUTIONS FOR JOBSITE ...9411
STARTING ENGINE ...9414
OPERATION ...9417
TRANSPORTATION ...9423
TOWING ...9424
PRECAUTIONS FOR MAINTENANCE ...9425
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ...9425
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ...9430
TIRES ...9435
OPERATION ...9436
GENERAL VIEW ...9437
GENERAL VIEW OF MACHINE ...9437
GENERAL VIEW OF CONTROLS AND GAUGES ...9438
EXPLANATION OF COMPONENTS ...9442
MACHINE MONITOR ...9442
SWITCHES ...9510
CONTROL LEVERS AND PEDALS ...9525
CAPS AND COVERS WITH LOCK ...9529
ASHTRAY ...9532
FRAME LOCK BAR ...9533
TOWING PIN ...9534
GREASE PUMP HOLDER ...9535
BATTERY DISCONNECT SWITCH ...9536
SYSTEM OPERATING LAMP ...9538
BACKUP ALARM ...9539
OPEN AND CLOSE CAB DOOR ...9540
FUSE ...9544
SLOW BLOW FUSE ...9546
AUXILIARY ELECTRIC POWER ...9547
HANDLING RADIO ...9548
HANDLING AUTO AIR CONDITIONER ...9553
HANDLING FRONT WIPER ...9564
HANDLING REAR VIEW MONITOR ...9565
HANDLING Komatsu Diesel Particulate Filter (KDPF) ...9566
HANDLING Komatsu Closed Crankcase Ventilation (KCCV) ...9574
HANDLING MACHINES EQUIPPED WITH KOMTRAX ...9575
MACHINE OPERATIONS AND CONTROLS ...9577
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...9577
STARTING ENGINE ...9601
CHECKS AFTER STARTING ENGINE ...9605
STOPPING ENGINE ...9608
MACHINE OPERATION ...9609
STEERING MACHINE ...9618
WORK EQUIPMENT CONTROLS AND OPERATIONS ...9620
HANDLING HYDRAULIC TYPE QUICK COUPLER ...9622
RECOMMENDED APPLICATIONS ...9626
RULES FOR OPERATION ...9632
ADJUST WORK EQUIPMENT POSTURE ...9634
PARKING MACHINE ...9641
CHECK AFTER FINISHING WORK ...9643
LOCKING ...9644
HANDLING TIRES ...9645
TRANSPORTATION ...9647
TRANSPORTATION PROCEDURE ...9647
LOADING AND UNLOADING WITH TRAILER ...9648
LIFTING MACHINE ...9652
COLD WEATHER OPERATION ...9654
COLD WEATHER OPERATION INFORMATION ...9654
AFTER DAILY WORK COMPLETION ...9655
IN COLD AREAS ...9655
AFTER COLD WEATHER SEASON ...9655
LONG-TERM STORAGE ...9656
BEFORE STORAGE ...9656
DURING STORAGE ...9656
AFTER STORAGE ...9657
STARTING MACHINE AFTER LONG-TERM STORAGE ...9657
TROUBLES AND ACTIONS ...9658
RUNNING OUT OF FUEL ...9658
TOWING MACHINE ...9659
DISCHARGED BATTERY ...9662
OTHER TROUBLE ...9666
MAINTENANCE ...9672
RULES FOR MAINTENANCE ...9673
SERVICE METER READING ...9673
KOMATSU GENUINE REPLACEMENT PARTS ...9673
KOMATSU GENUINE LUBRICANTS ...9673
ALWAYS USE CLEAN WASHER FLUID ...9673
FRESH AND CLEAN LUBRICANTS ...9673
CHECK DRAINED OIL AND USED FILTER ...9673
CAUTION FOR REFILLING OIL OR FUEL ...9673
WELDING INSTRUCTIONS ...9673
DO NOT DROP THINGS INSIDE MACHINE ...9673
PRECAUTIONS FOR KDPF ...9673
DUSTY JOBSITES ...9674
AVOID MIXING OIL ...9674
LOCKING INSPECTION COVERS ...9674
BLEED AIR FROM HYDRAULIC CIRCUIT ...9674
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ...9674
CHECKS AFTER INSPECTION AND MAINTENANCE ...9674
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ...9674
CLOSE ENGINE SIDE COVER SECURELY ...9675
OUTLINE OF MAINTENANCE ...9676
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ...9676
HANDLING ELECTRICAL COMPONENTS ...9680
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ...9681
TIGHTENING TORQUE LIST ...9681
MAINTENANCE SCHEDULE ...9682
MAINTENANCE SCHEDULE TABLE ...9682
MAINTENANCE PROCEDURE ...9684
EVERY 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 100 HOURS) ...9684
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ...9684
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) ...9684
WHEN REQUIRED ...9685
CHECKS BEFORE STARTING ...9715
EVERY 50 HOURS MAINTENANCE ...9716
EVERY 100 HOURS MAINTENANCE ...9717
EVERY 250 HOURS MAINTENANCE ...9719
EVERY 500 HOURS MAINTENANCE ...9726
EVERY 1000 HOURS MAINTENANCE ...9731
EVERY 2000 HOURS MAINTENANCE ...9737
EVERY 4000 HOURS MAINTENANCE ...9749
EVERY 4500 HOURS MAINTENANCE ...9751
EVERY 8000 HOURS MAINTENANCE ...9752
SPECIFICATIONS ...9754
SPECIFICATIONS ...9755
ATTACHMENTS AND OPTIONS ...9758
TIRE AND BUCKET SELECTION ...9759
HANDLING FORK ...9760
EXPLANATION OF COMPONENTS ...9760
MACHINE OPERATIONS AND CONTROLS ...9762
PCS (Proportional Control Switch) ...9765
DISPLAY OF LIQUID CRYSTAL UNIT ...9766
SETTING METHOD OF PCS ...9768
REPLACEMENT PARTS ...9770
SAFETY CRITICAL PARTS ...9771
SAFETY CRITICAL PARTS LIST ...9771
CONSUMABLE PARTS ...9772
CONSUMABLE PARTS LIST ...9772
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ...9773
LUBRICATION CHART ...9773
LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE AND RECOMMENDED GENUINE LUBRICANTS ...9775
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ...9777
INDEX ...9778
Komatsu Wheel Loader WA270 Repair Service Manual
