Komatsu WA500-7 Wheel Loader Service Repair Shop Manual (10001 and up) - SEN05693-03

This Complete Service Repair Workshop Manual PDF Download for the WA500-7 Komatsu Wheel Loader (SN: 10001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu WA500-7 Wheel Loader
Serial Numbers : 10001 and up


TABLE OF CONTENTS :

00 Index and foreword
01 Specification
10 Structure and function
20 Standard value tables
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and assembly
60 Maintenance standard
80 Appendix
90 Diagrams and drawings
INDEX


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEN05693-03
Total Pages : 2520


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COVER
00 Index and foreword
Index
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table

01 Specification
Table of contents
Specifications
Specification drawing
Specification
Weight table
Table of fuel, coolant, and lubricants

10 Structure and function
Table of contents
Engine and cooling system
Engine related parts
KVGT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDPF
Engine mount and transmission mount
Joint
Cooling system
Cooling fan pump
Cooling fan motor
Power train
Power train system
Drive shaft
Power train piping drawing
Transmission control
Torque converter
Torque converter regulator valve
Transmission
Transfer
Transmission control valve
Forward and reverse clutch ECMV and gear speed clutch ECMV
Lockup clutch ECMV
Main relief valve, torque converter relief valve, and main flow selector valve
Torque converter oil cooler
Center support
Lubricating oil relief valve
Axle
Differential
Final drive
Steering system
Layout of steering parts
Steering column
Joystick steering lever linkage
Steering pump
Steering control valve
Orbitrol valve
Stop valve
Emergency steering piping diagram
Diverter valve
Emergency steering pump
Brake system
Layout of brake parts
Charge valve
Brake valve
Slack adjuster
Accumulator (for brake)
Brake
Parking brake control
Parking brake
Parking brake solenoid valve
Parking brake emergency release valve
Undercarriage and frame
Axle mount
Center hinge pin
Tire
Hydraulic system
Hydraulic component layout
Work equipment control
Hydraulic tank
Double type gear pump
Work equipment pump
Control valve
CLSS
Hydraulic circuit diagram and names of valves
Accumulator charge valve
Work equipment lock solenoid valve
Accumulator (for PPC circuit)
Accumulator (for ECSS)
Work equipment
Work equipment linkage
Bucket
Bucket positioner and boom positioner
Lubrication of work equipment
Cab and its attachments
ROPS cab
Electrical system
Engine control system
Preheating system
Power mode selector circuit
Engine output limit function
Automatic warm-up function
Parking brake control system
System operating lamp function
Battery disconnect switch function
Backup lamp and brake lamp
Clearance lamp and headlamp
Working lamp
Horn circuit
Wiper and window washer circuit
Transmission controller system
Work equipment control system
Machine monitor system
Rear view monitor system
KOMTRAX system
System component parts
Sensor

20 Standard value tables
Table of contents
Standard service value table
Standard value table for engine
Standard value table for machine
Standard value table for electrical system

30 Testing and adjusting
Table of contents
General information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing boost pressure
Testing exhaust gas temperature
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing EGR valve and KVGT driving oil pressure
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no injection cranking operation
Testing of KDPF and muffler stack for looseness and damage
Testing of installed condition of cylinder head and manifolds
Testing engine piping for damage and looseness
Replacing and adjusting belt for alternator and air conditioner compressor
Procedures for cleaning fuel doser
Writing compensation values at replacement of injector and engine controller
Power train
Adjusting transmission output speed sensor
Adjusting transmission input speed sensor
Flushing procedure for torque converter and transmission hydraulic circuit
Retrieval of disabled machine due to transmission valve failure
Testing oil leakage from axle final drive
Testing drive shaft for looseness, backlash, and damage
Testing and adjusting power train oil pressure
Steering system
Testing directional lever
Testing steering wheel
Testing work equipment control lever
Testing and adjusting steering circuit oil pressure
Bleeding air from steering cylinder circuit.
Testing and adjusting steering stopper valve
Brake system
Testing brake pedal
Testing and adjusting brake pedal linkage
Adjustment procedure of transmission cut-off proximity switch of left brake pedal
Testing braking performance
Testing and adjusting of accumulator charge pressure
Testing wheel brake oil pressure
Testing lowering of wheel brake pressure
Testing wear of wheel brake disc
Bleeding air from wheel brake circuit
Releasing remaining pressure in brake accumulator circuit
Testing parking brake performance
Testing parking brake oil pressure
Testing wear of parking brake disc
Method of releasing parking brake manually
Hydraulic system
Testing fan speed
Testing fan pump circuit oil pressure
Bleeding air from hydraulic fan circuit
Testing work equipment EPC oil pressure
Testing and adjusting work equipment oil pressure
Bleeding air from work equipment circuit
Releasing remaining pressure from work equipment circuit
Checking of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
Work equipment
Testing and adjusting bucket position detection lever
Testing and adjusting boom position detection lever
Electrical system
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
Special functions of machine monitor
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service
Check sheet

40 Troubleshooting
Table of contents
General information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Check before troubleshooting
Inspection procedure before troubleshooting
Preparation work for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
Precautions on troubleshooting of machine monitor
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors)
Fabrication of short-circuit connector (for CA1883 and CA3135)
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [1500L0] Double Engagement of T/M Clutches
Failure code [15B0NX] Transmission Oil Filter Clogging
Failure code [15SAL1] Release Trouble of ECMV (Forward)
Failure code [15SALH] Malfunction of ECMV (Forward)
Failure code [15SBL1] Release Trouble of ECMV (Reverse)
Failure code [15SBLH] Malfunction of ECMV (Reverse)
Failure code [15SEL1] Release Trouble of ECMV (1st clutch)
Failure code [15SELH] Malfunction of ECMV (1st)
Failure code [15SFL1] Release Trouble of ECMV (2nd)
Failure code [15SFLH] Malfunction of ECMV (2nd)
Failure code [15SGL1] Release Trouble of ECMV (3rd)
Failure code [15SGLH] Malfunction of ECMV (3rd)
Failure code [15SHL1] Release Trouble of ECMV (4th)
Failure code [15SHLH] Malfunction of ECMV (4th)
Failure code [2F00MA] Failure of Parking Brake Circuit
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [989A00] Engine Overrun Prevention Activated
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [A1U0N3] HC Desorb Request 1
Failure code [A1U0N4] HC Desorb Request 2
Failure code [AA10NX] Air Cleaner Clogging
Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@CENS] T/C Oil Temp. Overheat
Failure code [B@HANS] HYD Oil Temp. Overheat
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sensor 2 Supply Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sensor 2 Supply Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sensor Supply Volt Error
Failure code [CA239] Ne Speed Sens Supply Volt High Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA273] PCV2 Short Error
Failure code [CA274] PCV2 Open Error
Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA323] Inj #5(L#5) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA325] Inj #6(L#6) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA332] Inj #4(L#4) Open/Short Error
Failure code [CA343] ECM Critical Internal Failure
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sensor 1 Supply Volt Low Error
Failure code [CA356] Mass Air Flow Sensor High Error
Failure code [CA357] Mass Air Flow Sensor Low Error
Failure code [CA386] Sensor 1 Supply Volt High Error
Failure code [CA431] Idle Validation Sw Error
Failure code [CA432] Idle Validation Process Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA515] Rail Press Sens Sup Volt High Error
Failure code [CA516] Rail Press Sens Sup Volt Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA555] Crankcase Press High Error 2
Failure code [CA556] Crankcase Press High Error 3
Failure code [CA559] Rail Press Low Error
Failure code [CA595] Turbo Speed High Error 2
Failure code [CA687] Turbo Speed Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA691] Intake Air Temp Sens High Error
Failure code [CA692] Intake Air Temp Sens Low Error
Failure code [CA697] ECM Internal Temp Sensor High Error
Failure code [CA698] ECM Int Temp Sensor Low Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1117] Persistent Data Lost Error
Failure code [CA1664] KDOC Malfunction
Failure code [CA1691] Regeneration Ineffective
Failure code [CA1695] Sensor 5 Supply Volt High Error
Failure code [CA1696] Sensor 5 Supply Volt Low Error
Failure code [CA1843] Crankcase Press Sens High Error
Failure code [CA1844] Crankcase Press Sens Low Error
Failure code [CA1879] KDPF Delta P Sensor High Error
Failure code [CA1881] KDPF Delta P Sensor Low Error
Failure code [CA1883] KDPF Delta P Sens In Range Error
Failure code [CA1921] KDPF Soot Load High Error 1
Failure code [CA1922] KDPF Soot Load High Error 2
Failure code [CA1923] Dosing Fuel Valve 1 High Error
Failure code [CA1924] Dosing Fuel Valve 1 Low Error
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error
Failure code [CA1927] Dosing Fuel Press Sens High Error
Failure code [CA1928] Dosing Fuel Press Sens Low Error
Failure code [CA1942] Crankcase Press Sens In Range Error
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error
Failure code [CA1977] Fuel Doser Open/Short Error
Failure code [CA1993] KDPF Delta Pressure Low Error
Failure code [CA2185] Throt Sensor Sup Volt High Error
Failure code [CA2186] Throt Sensor Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2265] Fuel Feed Pump Open Error
Failure code [CA2266] Fuel Feed Pump Short Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2349] EGR Valve Solenoid Open Error
Failure code [CA2353] EGR Valve Solenoid Short Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2381] KVGT Pos Sens High Error
Failure code [CA2382] KVGT Pos Sens Low Error
Failure code [CA2383] KVGT Solenoid Open Error
Failure code [CA2386] KVGT Solenoid Short Error
Failure code [CA2387] KVGT Servo Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [CA2637] KDOC Face Plugging
Failure code [CA2639] Manual Stationary Regeneration Request
Failure code [CA2732] Dosing Fuel Valve 2 High Error
Failure code [CA2733] Dosing Fuel Valve 2 Low Error
Failure code [CA2741] Dosing Fuel Valve Swap Error
Failure code [CA2765] Inj Trim Data Error
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error
Failure code [CA2881] Dosing Fuel Pressure Low Error 1
Failure code [CA3133] KDPF Outlet Press Sens High Error
Failure code [CA3134] KDPF Outlet Press Sens Low Error
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
Failure code [CA3167] Fuel Doser Degradation
Failure code [CA3251] KDOC Inlet Temp High Error
Failure code [CA3253] KDOC Temp Error - Non Regeneration
Failure code [CA3254] KDOC Outlet Temp High Error 1
Failure code [CA3255] KDPF Temp Error - Non Regeneration
Failure code [CA3256] KDPF Outlet Temp High Error 1
Failure code [CA3311] KDOC Outlet Temp High Error 2
Failure code [CA3312] KDPF Outlet Temp High Error 2
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
Failure code [CA3314] KDOC Inlet Temp Sens High Error
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
Failure code [CA3316] KDOC Outlet Temp Sens Low Error
Failure code [CA3317] KDOC Outlet Temp Sens High Error
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
Failure code [CA3319] KDPF Outlet Temp Sens High Error
Failure code [CA3321] KDPF Outlet Temp Sens Low Error
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Failure code [D160KA] Disconnection of Backup Lamp Relay Output
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output
Failure code [D160KY] Hot Short of Backup Lamp Relay Output
Failure code [D191KA] Disconnection of Neutral Output Relay
Failure code [D191KB] Ground Fault of Neutral Output Relay
Failure code [D191KY] Hot Short of Neutral Output Relay
Failure code [D192KA] Disconnection of ECSS Solenoid
Failure code [D192KB] Ground Fault of ECSS Solenoid
Failure code [D192KY] Hot Short of ECSS Solenoid
Failure code [D193KA] Disconnection of J/S Solenoid Cut Relay
Failure code [D193KB] Ground Fault of J/S Solenoid Cut Relay
Failure code [D193KY] Hot Short of J/S Solenoid Cut Relay
Failure code [D193MC] Malfunction of J/S Solenoid Cut Relay
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D1E6KA] Disconnection of Parking Brake Relay
Failure code [D1E6KB] Ground Fault of Parking Brake Relay
Failure code [D1E6KY] Hot Short of Parking Brake Relay
Failure code [D5ZHKA] Failure of Key SW C Signal
Failure code [D5ZHKB] Key SW C Signal Short Circuit
Failure code [D5ZHKZ] Failure of Key SW C Signal
Failure code [D5ZHL6] Disconnection of Key SW C
Failure code [D811MC] KOMTRAX Error
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)
Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MC] Monitor Error
Failure code [DAF3KK] Controller Power Source Low (MON)
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit
Failure code [DAFGMC] GPS Module Error
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)
Failure code [DAFQKR] CAN2 Discon (Monitor)
Failure code [DAQ0KK] Controller Power Source Low (T/M)
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
Failure code [DAQ0MC] T/M Con Error
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M)
Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M)
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M)
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M)
Failure code [DAQQKR] CAN2 Discon (Transmission Con)
Failure code [DAQRKR] CAN1 Discon (Transmission Con)
Failure code [DAQRMA] Inconsistency of Option Selection (T/M)
Failure code [DAZ9KQ] A/C Model Selection Abnormality
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
Failure code [DB2QKR] CAN2 Discon (Engine Con)
Failure code [DB2RKR] CAN1 Discon (Engine Con)
Failure code [DB90KK] Drop in BBC Controller Main Power Source
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC)
Failure code [DB90MC] BBC Error
Failure code [DB91KA] Disconnection of Key SW ACC (BBC)
Failure code [DB92KK] Solenoid Power Source Low (BBC)
Failure code [DB95KX] Failure of 5 V Power Source 1
Failure code [DB96KX] Failure of 5 V Power Source 2
Failure code [DB99KQ] Inconsistency of Model Selection (BBC)
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC)
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con)
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con)
Failure code [DB9RMA] Inconsistency of Option Selection (BBC)
Failure code [DBE5KX] Failure of 5V Power Source
Failure code [DBE6KX] Failure of 24 V Power Source
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW
Failure code [DDA8KY] Hot Short of Throttle Lock Set SW
Failure code [DDA9KY] Hot Short of Throttle Lock Resume SW
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch
Failure code [DDB6L4] Neutral Signal Malfunction
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch
Failure code [DDE5KA] Failure of Emergency Steering Signal
Failure code [DDK3KA] FNR SW Input Signal Disconnection
Failure code [DDK3KB] FNR SW Input Signal Short Circuit
Failure code [DDK4KA] J/S FNR Input Signal Disconnection
Failure code [DDK4KB] J/S FNR Input Signal Short Circuit
Failure code [DDK5L4] Failure of J/S Shift Up/Down SW
Failure code [DDK6KA] FNR Lever Input Signal Disconnection
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW
Failure code [DDT0L4] Failure of Shift Mode Select SW
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal
Failure code [DDW9LD] Ground Fault of Kickdown Switch
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW
Failure code [DF10KA] Disconnection of Shift Lever Input
Failure code [DF10KB] Ground Fault of Shift Lever Input
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor
Failure code [DH21KA] Failure of Loader Pump Press. Sensor
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S.
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor
Failure code [DHT2L6] Failure of T/M Oil Filter Sensor Circuit
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit
Failure code [DHT8ZG] Steering Oil Pressure Low
Failure code [DJF1KA] Disconnection of Fuel Level Sensor
Failure code [DK55KA] Failure of FNR Lever Potentio
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit
Failure code [DK55L5] Failure of FNR Lever Potentio
Failure code [DK59KA] Failure of Boom Lever Potentio (Main)
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main)
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub)
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub)
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main)
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main)
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub)
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub)
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main)
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main)
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub)
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub)
Failure code [DK5FKA] Failure of J/S Lever Potentio (Main)
Failure code [DK5FKY] Hot Short of J/S Lever Potentio (Main)
Failure code [DK5FL8] J/S Lever Potentio (Main & Sub) Disagree
Failure code [DK5GKA] Failure of J/S Lever Potentio (Sub)
Failure code [DK5GKY] Hot Short of J/S Lever Potentio (Sub)
Failure code [DKA0KA] Failure of Boom Angle Sensor
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit
Failure code [DKA0L0] Boom Angle Sensor Dislocation
Failure code [DKA1KA] Failure of Bucket Angle Sensor
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
Failure code [DLF1LC] Failure of T/M Input Speed Sensor
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main)
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)
Failure code [DPQ1KR] LIN Discon (Switch Panel)
Failure code [DPQ2KR] LIN Discon (LED Unit)
Failure code [DPQ3KR] LIN Discon (Rear View Monitor)
Failure code [DSJ0KR] CAN2 Discon (Meter Unit)
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic.
Failure code [DV00KB] Ground Fault of Buzzer Output
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol.
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol.
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol.
Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise)
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise)
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise)
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower)
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower)
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower)
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt)
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt)
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt)
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump)
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump)
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump)
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol.
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol.
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom)
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom)
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom)
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket)
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket)
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol.
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol.
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol.
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward)
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward)
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward)
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)
Failure code [DXHLKA] Disconnection of J/S Right EPC Solenoid
Failure code [DXHLKB] Ground Fault of J/S Right EPC Solenoid
Failure code [DXHLKY] Hot Short of J/S Right EPC Solenoid
Failure code [DXHMKA] Disconnection of J/S Left EPC Solenoid
Failure code [DXHMKB] Ground Fault of J/S Left EPC Solenoid
Failure code [DXHMKY] Hot Short of J/S Left EPC Solenoid
Failure code [LA00L3] Failure of Fan Reverse
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)
E-2 Manual preheating system does not work
E-3 Automatic preheating system does not work
E-4 While preheating is working, preheating monitor does not light up
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing
E-6 LCD unit on machine monitor displays nothing
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers)
E-8 LCD on machine monitor does not display properly
E-9 Meter unit display on machine monitor is abnormal
E-10 Night lighting lamp of meter unit on machine monitor is abnormal
E-11 Caution LED on machine monitor is abnormal
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly
E-13 Two switches operation of switch panel on machine monitor does not function
E-14 Switch panel buzzer of machine monitor is abnormal
E-15 Rearview monitor does not light up or backlight flickers
E-16 Rearview monitor images are not displayed clearly
E-17 Rearview monitor brightness cannot be adjusted
E-18 Night lighting lamp of rearview monitor is abnormal
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light
E-22 Air cleaner clogging indicator lamp does not light
E-23 Radiator coolant level caution lamp does not light
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light
E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light
E-26 Fuel level gauge does not indicate correct level
E-27 Seat belt caution lamp indication is abnormal
E-28 Horn does not sound
E-29 Horn does not stop sounding
E-30 Alarm buzzer does not sound
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding
E-32 Kickdown does not work when kickdown switch is turned ON
E-33 The hold switch does not work when it is pressed
E-34 Transmission is always shifted to Neutral, or the brake drags when parking brake applies and FR drive is selected
E-35 Transmission cut-off mode is not selected or not released
E-36 Transmission cut-off setting cannot be released
E-37 FNR switch mode is not selected or not released
E-38 When operating engine mode selector switch, engine mode selector function does not operate properly
E-39 Flow of loader pump does not increase from the minimum rate
E-40 ECSS function cannot be selected or cannot be released
E-41 None of headlamp, clearance lamp, and tail lamp lights
E-42 Clearance lamp and tail lamp do not light up or go out
E-43 Both High and Low beams of headlamp do not light up or go out
E-44 Low beam of headlamp does not light up or go out
E-45 High beam of headlamp does not light up or go out
E-46 Front working lamp does not light up or go out
E-47 Rear working lamp does not light up or go out
E-48 All of turn signal lamps and hazard lamps do not light up or go out
E-49 Turn signal lamps do not light up or go out
E-50 Hazard lamp does not light up or go out
E-51 Brake lamp does not light up or stays lighted
E-52 Backup lamp does not light or continues to light
E-53 Backup buzzer does not sound or continues to sound
E-54 Front wiper does not operate
E-55 Rear wiper does not operate
E-56 Window washer does not operate
E-57 Fuel feed pump does not operate or stop automatically
E-58 KOMTRAX system does not operate properly
Troubleshooting of hydraulic and mechanical system (H-mode)
Information described in troubleshooting table (H-mode)
System chart of hydraulic and mechanical systems
Failure mode and cause table
H-1 Machine does not start
H-2 Torque converter lockup clutch is not disengaged (engine stalls)
H-3 Torque converter lockup clutch is not engaged
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift
H-5 Large shock is made when machine starts or gear is shifted
H-6 Machine starts or gear speed shifts with long time lag
H-7 Torque converter oil temperature is high
H-8 Machine does not turn
H-9 Turning response is poor
H-10 Steering wheel is heavy to turn
H-11 Machine sways or large shocks are made while machine turns
H-12 Turning radius differs between right and left turns
H-13 Wheel brakes do not work or are weak
H-14 Wheel brakes are not released or drag
H-15 Parking brake does not work or it is weak
H-16 Parking brake is not released or drags (including emergency release system)
H-17 Boom does not rise
H-18 Boom moves slow or boom lacks lifting force
H-19 Rising boom slows down at certain height
H-20 Lift cylinders do not serve to hold bucket on ground
H-21 Hydraulic drift of boom is large
H-22 Boom moves up and down during operation
H-23 Bucket does not tilt back
H-24 Bucket moves slow or bucket lacks tilt-back force
H-25 Bucket decelerates during tilt-back operation
H-26 Bucket cylinder does not hold bucket on ground
H-27 Hydraulic drift of bucket is large
H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD)
H-29 Boom and bucket control levers do not move smoothly and are heavy to move
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall
H-31 Large shocks are made when work equipment starts to move and stops
H-32 When certain work equipment stalls hydraulically, other work equipment moves
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces
H-34 Fan speed is abnormal (too high or low, or fan does not rotate)
H-35 Unusual noise is heard from around fan
Troubleshooting of engine (S-mode)
Information mentioned in troubleshooting table (S mode)
S-1 When starting switch is turned to START position, engine is not cranked
S-2 The engine cranks but exhaust smoke does not come out
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not)
S-4 Engine startability is poor
S-5 Engine does not pick-up smoothly
S-6 Engine stops during operation
S-7 Engine runs rough or is unstable
S-8 Engine lacks power
S-9 KDPF gets clogged in a short time
S-10 Engine oil consumption is excessive
S-11 Engine oil becomes contaminated early
S-12 Fuel consumption is excessive
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
S-14 Oil pressure drops
S-15 Fuel mixes into engine oil
S-16 Water mixes into engine oil (milky)
S-17 Coolant temperature rises too high (overheating)
S-18 Unusual noise is heard
S-19 Vibration is excessive
S-20 Air cannot be bled from fuel circuit
S-21 Active regeneration is executed frequently
S-22 Active regeneration takes a long time
S-23 White smoke is exhausted during active regeneration

50 Disassembly and assembly
Table of contents
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of engine hood assembly
Removal and installation of radiator core assembly
Removal and installation of aftercooler
Removal and installation of hydraulic oil cooler
Removal and installation of power train oil cooler assembly
Removal and installation of engine assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of cooling fan and fan motor assembly
Removal and installation of KDPF assembly
Disassembly and assembly of KDPF assembly
Removal and installation of KCCV assembly
Removal and installation of KVGT assembly
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
Removal and installation of air cleaner assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser assembly
Removal and installation of belt for alternator and air conditioner compressor
Removal and installation of fuel tank assembly
Power train
Removal and installation of power train unit assembly
Disconnection and connection of power train unit assembly
Disassembly and assembly of input transfer assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Disassembly and assembly of transfer and parking brake assembly
Removal and installation of front differential assembly
Disassembly and assembly of differential assembly (with LSD)
Disassembly and assembly of differential assembly (without LSD)
Removal and installation of front axle assembly
Removal and installation of rear axle assembly
Disassembly and assembly of final drive assembly (front and rear)
Steering system
Removal and installation of steering valve assembly
Brake system
Removal and installation of brake assembly (front and rear)
Disassembly and assembly of brake assembly (front and rear)
Disassembly and assembly of slack adjuster assembly
Disassembly and assembly of brake accumulator charge valve assembly
Undercarriage and frame
Removal and installation of center hinge pin
Removal and installation of large counterweight assembly
Removal and installation of small counterweight assembly
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of work equipment pump assembly
Removal and installation of steering and power train pump assembly
Removal and installation of cooling fan pump assembly
Removal and installation of work equipment control valve assembly
Disassembly and assembly of work equipment control valve assembly
Removal and installation of diverter valve assembly
Disassembly and assembly of steering cylinder assembly
Disassembly and assembly of work equipment cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator's cab assembly (separate cab and floor specification)
Removal and installation of operator's cab glass (stuck window glass)
Removal and installation of operator's seat assembly
Removal and installation of seat belt
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of machine monitor assembly
Removal and installation of work equipment controller assembly
Removal and installation of rear view monitor assembly
Removal and installation of engine controller assembly
Removal and installation of transmission controller assembly
Removal and installation of monitor controller assembly
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal assembly

60 Maintenance standard
Table of contents
Engine and cooling system
Engine mount and transmission mount
Joint
Cooling fan pump
Servo valve
Cooling fan motor
Power train
Drive shaft
Torque converter
Torque converter regulator valve
Transmission
Transmission control valve
Forward and reverse clutch ECMV and gear speed clutch ECMV
Lockup clutch ECMV
Main relief valve, torque converter relief valve, and main flow selector valve
Center support
Lubricating oil relief valve
Axle
Differential
Final drive
Steering system
Steering column
Steering pump
Steering control valve
Steering cylinder
Diverter valve
Emergency steering pump
Brake system
Charge valve
Brake valve
Slack adjuster
Accumulator (for brake)
Brake
Parking brake
Parking brake solenoid valve
Undercarriage and frame
Axle mount
Center hinge pin
Hydraulic system
Hydraulic tank
Double type gear pump
Work equipment pump
Control valve
Accumulator charge valve
Work equipment
Work equipment linkage
Bucket
Bucket positioner and boom positioner
Work equipment cylinder

80 Appendix
Table of contents
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Condenser
Receiver drier
Sunlight sensor
Outer temperature sensor (outside air temperature sensor)
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
Parts and connectors layout
Testing with self-diagnosis function
Testing temperature control system
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Check evaporator temperature sensor
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information in troubleshooting table
Failure code list related to air conditioner
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
Handling of compressor oil

90 Diagrams and drawings
Table of contents
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Power train hydraulic circuit diagram
Brake hydraulic circuit diagram
Hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram
Electrical circuit diagram
Electrical circuit diagram of floor

INDEX

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