Komatsu WA320-7 Install guide
WHEEL LOADER
SEN06202-03
WA320-7
SERIAL NUMBERS
80001
and up
00 Index and foreword
Index
Index
(ALL-0310-001-A-00-A)
00 Index and foreword .......................................................................................................................00-1
Index .........................................................................................................................................00-2
Foreword, safety and general information ................................................................................... 00-17
Important safety notice ....................................................................................................... 00-17
How to read the shop manual..............................................................................................00-24
Explanation of terms for maintenance standard .................................................................... 00-26
Handling equipment of fuel system devices .......................................................................... 00-28
Handling of intake system parts........................................................................................... 00-29
Handling of hydraulic equipment.......................................................................................... 00-30
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-32
Handling of electrical equipment.......................................................................................... 00-35
How to read electric wire code............................................................................................. 00-43
Precautions when performing operation ............................................................................... 00-46
Practical use of KOMTRAX................................................................................................. 00-51
Standard tightening torque table.......................................................................................... 00-52
List of abbreviation ............................................................................................................. 00-58
Conversion table................................................................................................................ 00-63
01 Specification.................................................................................................................................01-1
Table of contents ........................................................................................................................01-2
Specifications.............................................................................................................................01-3
Specification drawing ...........................................................................................................01-3
Specifications ......................................................................................................................01-7
Weight table ...................................................................................................................... 01-17
Table of fuel, coolant, and lubricants .................................................................................... 01-21
10 Structure and function ...................................................................................................................10-1
Table of contents ........................................................................................................................10-2
Engine and cooling system..........................................................................................................10-4
Engine related parts .............................................................................................................10-4
KVGT..................................................................................................................................10-6
EGR system piping drawing................................................................................................ 10-13
EGR system circuit diagram................................................................................................ 10-15
EGR valve......................................................................................................................... 10-17
EGR cooler........................................................................................................................ 10-19
KCCV layout drawing ......................................................................................................... 10-20
KCCV ventilator ................................................................................................................. 10-22
KDPF................................................................................................................................ 10-24
Cooling system .................................................................................................................. 10-28
Cooling fan motor............................................................................................................... 10-30
Power train............................................................................................................................... 10-40
Power train system............................................................................................................. 10-40
Layout of power train parts.................................................................................................. 10-42
Damper............................................................................................................................. 10-43
HST pump......................................................................................................................... 10-44
HST motor1....................................................................................................................... 10-57
HST motor2....................................................................................................................... 10-59
Transfer ............................................................................................................................ 10-64
Clutch solenoid valve ......................................................................................................... 10-71
Drive shaft......................................................................................................................... 10-73
Axle .................................................................................................................................. 10-74
Differential......................................................................................................................... 10-76
Torque proportional differential ............................................................................................ 10-80
Limited slip differential ........................................................................................................ 10-82
Final drive ......................................................................................................................... 10-87
Steering system........................................................................................................................ 10-89
Layout of steering devices .................................................................................................. 10-89
Steering column................................................................................................................. 10-90
Priority valve...................................................................................................................... 10-91
Cushion valve.................................................................................................................... 10-95
00-2 WA320-7
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00 Index and foreword
Index
Emergency steering valve................................................................................................... 10-96
Orbitrol valve ..................................................................................................................... 10-99
Brake system ......................................................................................................................... 10-105
Layout of brake parts........................................................................................................ 10-105
Brake accumulator charge valve........................................................................................ 10-107
Brake valve ..................................................................................................................... 10-112
Brake accumulator ........................................................................................................... 10-116
Slack adjuster.................................................................................................................. 10-117
Brake.............................................................................................................................. 10-119
Parking brake control ....................................................................................................... 10-122
Parking brake .................................................................................................................. 10-123
Parking brake solenoid valve ............................................................................................ 10-124
Undercarriage and frame......................................................................................................... 10-126
Axle mount ...................................................................................................................... 10-126
Center hinge pin .............................................................................................................. 10-128
Tire ................................................................................................................................. 10-129
Hydraulic system .................................................................................................................... 10-131
Hydraulic component layout.............................................................................................. 10-131
Work equipment control.................................................................................................... 10-133
Hydraulic tank.................................................................................................................. 10-134
Double type gear pump .................................................................................................... 10-137
Steering and work equipment pump................................................................................... 10-138
Control valve ................................................................................................................... 10-150
CLSS.............................................................................................................................. 10-160
Hydraulic circuit diagram and names of valves.................................................................... 10-164
Self-pressure reducing valve............................................................................................. 10-177
Work equipment PPC valve .............................................................................................. 10-182
Work equipment lock solenoid valve .................................................................................. 10-190
PPC circuit accumulator ................................................................................................... 10-191
ECSS accumulator........................................................................................................... 10-192
Work equipment ..................................................................................................................... 10-193
Work equipment linkage ................................................................................................... 10-193
Bucket ............................................................................................................................ 10-194
Cab and its attachments.......................................................................................................... 10-195
ROPS cab ....................................................................................................................... 10-195
Cab mount ...................................................................................................................... 10-197
Electrical system .................................................................................................................... 10-198
Engine control system ...................................................................................................... 10-198
Preheating system ........................................................................................................... 10-201
Engine output limit function ............................................................................................... 10-203
Automatic warm-up function.............................................................................................. 10-204
Parking brake control system ............................................................................................ 10-205
System operating lamp function......................................................................................... 10-209
Battery disconnect switch function ..................................................................................... 10-210
HST controller system....................................................................................................... 10-212
Machine monitor system................................................................................................... 10-252
Rearview monitor system.................................................................................................. 10-273
KOMTRAX system........................................................................................................... 10-276
System component parts .................................................................................................. 10-279
Sensor ............................................................................................................................ 10-302
20 Standard value tables....................................................................................................................20-1
Table of contents ........................................................................................................................20-2
Standard service value table........................................................................................................20-3
Standard value table for engine .............................................................................................20-3
Standard value table for machine ..........................................................................................20-5
Standard value table for electrical system............................................................................. 20-17
30 Testing and adjusting ....................................................................................................................30-1
Table of contents ........................................................................................................................30-2
Related information on testing and adjusting ................................................................................. 30-4
WA320-7 00-3
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00 Index and foreword
Index
Tools for testing and adjusting ...............................................................................................30-4
Sketch of tools for testing and adjusting ............................................................................... 30-10
Engine and cooling system........................................................................................................ 30-11
Testing engine speed ......................................................................................................... 30-11
Testing boost pressure ....................................................................................................... 30-12
Testing exhaust gas temperature......................................................................................... 30-14
Testing exhaust gas color ...................................................................................................30-15
Testing and adjusting valve clearance .................................................................................. 30-17
Testing compression pressure............................................................................................. 30-20
Testing blowby pressure ..................................................................................................... 30-24
Testing engine oil pressure ................................................................................................. 30-25
Testing EGR valve and KVGT oil pressures .......................................................................... 30-26
Testing fuel pressure .......................................................................................................... 30-27
Testing fuel discharge, return and leakage............................................................................ 30-32
Bleeding air from fuel system ..............................................................................................30-37
Testing fuel circuit for leakage .............................................................................................30-39
Handling cylinder cutout mode operation.............................................................................. 30-40
Handling no-injection cranking operation .............................................................................. 30-41
Testing of KDPF and muffler stack for looseness and damage ............................................... 30-42
Testing of installed condition of cylinder heads and manifolds ................................................ 30-43
Testing engine piping for damage and looseness .................................................................. 30-44
Testing and adjusting air conditioner compressor belt tension ................................................ 30-45
Replacing alternator belt ..................................................................................................... 30-46
Power train............................................................................................................................... 30-47
Testing oil leakage from axle final drive ................................................................................ 30-47
Testing drive shaft for looseness, backlash, and damage....................................................... 30-48
Testing accelerator pedal .................................................................................................... 30-49
Testing and adjusting HST oil pressure................................................................................. 30-50
Testing transfer clutch control pressure ................................................................................ 30-53
Steering system........................................................................................................................ 30-54
Testing directional lever ...................................................................................................... 30-54
Testing steering wheel ........................................................................................................ 30-55
Testing work equipment control lever ................................................................................... 30-57
Testing and adjusting steering circuit oil pressure.................................................................. 30-59
Bleeding air from steering cylinder circuit ............................................................................. 30-61
Brake system ........................................................................................................................... 30-62
Testing brake pedal ............................................................................................................ 30-62
Testing braking performance ............................................................................................... 30-63
Testing and adjusting of accumulator charge pressure........................................................... 30-64
Testing wheel brake oil pressure.......................................................................................... 30-66
Testing lowering of wheel brake pressure ............................................................................. 30-67
Testing wear of wheel brake disc .........................................................................................30-69
Bleeding air from wheel brake circuit.................................................................................... 30-70
Releasing remaining pressure in brake accumulator circuit .................................................... 30-71
Testing parking brake performance ...................................................................................... 30-72
Testing wear of parking brake disc ....................................................................................... 30-73
Testing parking brake release pressure ................................................................................ 30-74
Method of releasing parking brake manually......................................................................... 30-75
Hydraulic system ...................................................................................................................... 30-76
Testing cooling fan speed ................................................................................................... 30-76
Testing cooling fan pump circuit oil pressure ......................................................................... 30-77
Bleeding air from hydraulic fan circuit................................................................................... 30-79
Testing and adjusting work equipment PPC oil pressure ........................................................ 30-80
Testing and adjusting work equipment oil pressure................................................................ 30-82
Bleeding air from work equipment circuit .............................................................................. 30-86
Releasing remaining pressure from work equipment circuit.................................................... 30-87
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with
nitrogen gas ......................................................................................................... 30-89
Work equipment ....................................................................................................................... 30-93
00-4 WA320-7
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00 Index and foreword
Index
Testing and adjusting bucket positioner and bucket proximity switch....................................... 30-93
Testing and adjusting boom position detection lever .............................................................. 30-95
Electrical system ...................................................................................................................... 30-96
Adjusting replaced, reassembled or added sensor, controller, etc. with machine
monitor ................................................................................................................ 30-96
Special functions of machine monitor ................................................................................... 30-97
Adjusting rearview camera angle....................................................................................... 30-176
Handling voltage circuit of engine controller........................................................................ 30-177
Handling battery disconnect switch .................................................................................... 30-178
Testing diodes ................................................................................................................. 30-179
Pm clinic ................................................................................................................................ 30-180
Pm Clinic service ............................................................................................................. 30-180
Check sheet .................................................................................................................... 30-181
40 Troubleshooting............................................................................................................................40-1
Table of contents ........................................................................................................................40-2
Related information on troubleshooting....................................................................................... 40-10
Troubleshooting points ....................................................................................................... 40-10
Sequence of events in troubleshooting................................................................................. 40-12
Checks before troubleshooting............................................................................................ 40-14
Inspection procedure before troubleshooting ........................................................................ 40-16
Preparation for troubleshooting of electrical system............................................................... 40-33
Classification and procedures for troubleshooting ................................................................. 40-39
Symptom and troubleshooting numbers ............................................................................... 40-42
Information in troubleshooting table ..................................................................................... 40-45
Procedure for troubleshooting wiring harness of pressure sensor system for open
circuit................................................................................................................... 40-47
Connector list and layout .................................................................................................... 40-50
Connector contact identification........................................................................................... 40-64
T-branch box and T-branch adapter table ........................................................................... 40-103
Fuse location table ........................................................................................................... 40-108
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ..................................40-111
Precautions when performing troubleshooting of machine monitor........................................ 40-114
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit.................................................................................................................... 40-116
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-121
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) .......................................................................................................... 40-122
Failure codes table........................................................................................................... 40-123
Troubleshooting by failure code (Display of code) ...................................................................... 40-135
Failure code [2F00MA] Failure of Parking Brake Circuit ....................................................... 40-135
Failure code [2F00MB] Malfunction of Parking Brake .......................................................... 40-138
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-140
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-142
Failure code [6091NX] HST Oil Filter Clogging ................................................................... 40-144
Failure code [7RHYKA] Disconnection of Fan Variable Control Sol. ...................................... 40-146
Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol......................................... 40-148
Failure code [7RHYKY] Hot Short of Fan Variable Control Sol. ............................................. 40-150
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-152
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-153
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-154
Failure code [879BKB] A/C Outer Sensor Short Circuit........................................................ 40-155
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-156
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-157
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-158
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-159
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-160
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-161
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-162
WA320-7 00-5
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00 Index and foreword
Index
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-163
Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-164
Failure code [A1U0N4] HC Desorb Request 2 .................................................................... 40-166
Failure code [AA10NX] Air Cleaner Clogging...................................................................... 40-168
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-170
Failure code [AB00KY] Hot Short of Alternator R Terminal ................................................... 40-171
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-172
Failure code [B@BAZK] Engine Oil Level Low.................................................................... 40-173
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-175
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-176
Failure code [B@CRNS] HST Oil Temp. Overheat .............................................................. 40-178
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-179
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-180
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-182
Failure code [CA131] Throttle Sensor High Error................................................................. 40-184
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-186
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-188
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-190
Failure code [CA153] Chg Air Temp Sensor High Error........................................................ 40-192
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-194
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-196
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-198
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-200
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-202
Failure code [CA234] Eng Overspeed ................................................................................ 40-203
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-204
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-205
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-206
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-208
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-210
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-211
Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-213
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-215
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-217
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-219
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-221
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-223
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-224
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-225
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-227
Failure code [CA357] Mass Air Flow Sensor Low Error........................................................ 40-229
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-231
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-232
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-234
Failure code [CA431] Idle Validation Sw Error..................................................................... 40-236
Failure code [CA432] Idle Validation Process Error ............................................................. 40-239
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-242
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-243
Failure code [CA442] Battery Voltage High Error................................................................. 40-245
Failure code [CA449] Rail Press Very High Error................................................................. 40-246
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-247
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-249
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-251
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-252
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-254
Failure code [CA553] Rail Press High Error ........................................................................ 40-256
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-257
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-258
Failure code [CA559] Rail Press Low Error......................................................................... 40-259
00-6 WA320-7
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00 Index and foreword
Index
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-261
Failure code [CA687] Turbo Speed Low Error..................................................................... 40-262
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-264
Failure code [CA691] Intake Air Temp Sens High Error........................................................ 40-266
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-268
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-270
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-271
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-272
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-274
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-279
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-280
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-283
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-286
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-287
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-289
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-291
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-293
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-295
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-297
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-301
Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-304
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-309
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-310
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-313
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-315
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-317
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-318
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-320
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-323
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-324
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-325
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-327
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-329
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-330
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-332
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-334
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-336
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-338
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-340
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-343
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-345
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-347
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-348
Failure code [CA2555] Grid Htr Relay Volt Low Error........................................................... 40-349
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-351
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-353
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-355
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-358
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-359
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-360
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-362
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-364
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-368
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-371
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-375
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-378
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-382
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-385
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-389
WA320-7 00-7
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00 Index and foreword
Index
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-393
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-396
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-399
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-403
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-406
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-409
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-413
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-416
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-419
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-423
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error......................................... 40-425
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-427
Failure code [D110L4] Disconnection of Battery Relay Signal............................................... 40-428
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................................... 40-430
Failure code [D160KY] Hot Short of Backup Lamp Relay Output .......................................... 40-432
Failure code [D191KA] Disconnection of Neutral Output Relay............................................. 40-434
Failure code [D191KB] Ground Fault of Neutral Output Relay .............................................. 40-436
Failure code [D191KY] Hot Short of Neutral Output Relay.................................................... 40-438
Failure code [D192KA] Disconnection of ECSS Solenoid..................................................... 40-440
Failure code [D192KB] Ground Fault of ECSS Solenoid ...................................................... 40-442
Failure code [D192KY] Hot Short of ECSS Solenoid ........................................................... 40-443
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-444
Failure code [D1B0KA] Disconnection of HST Safety Relay................................................. 40-446
Failure code [D1B0KB] Ground Fault of HST Safety Relay .................................................. 40-448
Failure code [D1B0KY] Hot Short of HST Safety Relay........................................................ 40-450
Failure code [D1B0MC] Malfunction of HST Safety Relay .................................................... 40-452
Failure code [D1E6KA] Disconnection of Parking Brake Relay ............................................. 40-453
Failure code [D1E6KB] Ground Fault of Parking Brake Relay............................................... 40-455
Failure code [D1E6KY] Hot Short of Parking Brake Relay .................................................... 40-457
Failure code [D5ZHKA] Failure of Key SW C Signal ............................................................ 40-459
Failure code [D5ZHKB] Key SW C Signal Short Circuit........................................................ 40-461
Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-463
Failure code [D811MC] KOMTRAX Error............................................................................ 40-464
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-465
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-466
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-468
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-470
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-471
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-473
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-474
Failure code [DAF0MC] Monitor Error ................................................................................ 40-475
Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-476
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-478
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-479
Failure code [DAFGMC] GPS Module Error........................................................................ 40-480
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-481
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-483
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-485
Failure code [DAJ0KK] Controller Power Source Low (HST) ................................................ 40-486
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST)....................................... 40-489
Failure code [DAJ0MC] HST Con Error .............................................................................. 40-490
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST).............................................. 40-491
Failure code [DAJ2KK] Solenoid Power Source Low (HST) ................................................. 40-493
Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay ........................................... 40-496
Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay .................................................... 40-498
Failure code [DAJ5KX] Failure of 5V Power Source 0.......................................................... 40-500
Failure code [DAJ6KX] Failure of 5V Power Source 1.......................................................... 40-502
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) .......................................... 40-504
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) ................................................ 40-505
00-8 WA320-7
Find manuals at https://best-manuals.com
00 Index and foreword
Index
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) ................................................ 40-507
Failure code [DAJQKR] CAN2 Discon ( HST Con) .............................................................. 40-509
Failure code [DAJRKR] CAN1 Discon ( HST Con) .............................................................. 40-510
Failure code [DAJRMA] Inconsistency of Option Selection (HST) ......................................... 40-511
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-512
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-513
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-514
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-519
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................... 40-523
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-525
Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction .............................................. 40-527
Failure code [DDB6L4] Parking Brake Signal Malfunction .................................................... 40-529
Failure code [DDD7KA] Failure of Variable Speed Control ................................................... 40-532
Failure code [DDD7KY] Hot Short of Variable Speed Control ............................................... 40-534
Failure code [DDK3KA] FNR SW Input Signal Disconnection............................................... 40-536
Failure code [DDK3KB] FNR SW Input Signal Short Circuit.................................................. 40-538
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ............................................ 40-540
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit............................................... 40-543
Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch ....................................... 40-545
Failure code [DF10KA] Disconnection of Speed Range Input ............................................... 40-547
Failure code [DF10KB] Ground Fault of Speed Range Input ................................................ 40-550
Failure code [DGH1KX] Out of Range of HST Oil Temp. Sensor........................................... 40-553
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ......................................... 40-555
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .................................................. 40-557
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ............................................... 40-559
Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA) ........................................ 40-561
Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA) .................................... 40-563
Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB) ........................................ 40-565
Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB) .................................... 40-567
Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom) ......................................... 40-569
Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom) ..................................... 40-571
Failure code [DHPEKA] Failure of Steering & Loader Pump Press........................................ 40-573
Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press.................................... 40-575
Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit ........................................ 40-577
Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit .................................... 40-579
Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit ....................................... 40-581
Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit.................................... 40-583
Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit...................................... 40-585
Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit.................................. 40-587
Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit .......................................... 40-589
Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit ...................................... 40-591
Failure code [DHT8ZG] Steering Oil Pressure Low.............................................................. 40-593
Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit ............................................ 40-594
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................................................. 40-596
Failure code [DK55KA] Failure of FNR Lever Potentio......................................................... 40-598
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ........................................... 40-601
Failure code [DK55L5] Failure of FNR Lever Potentio.......................................................... 40-603
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ................................................ 40-604
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ............................................ 40-607
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree........................................ 40-610
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub).................................................. 40-613
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub).............................................. 40-616
Failure code [DK70KA] Failure of inching sensor Circuit ...................................................... 40-619
Failure code [DK70KY] Hot Short of inching sensor Circuit .................................................. 40-622
Failure code [DKA0KA] Failure of Boom Angle Sensor ........................................................ 40-624
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .......................................... 40-626
Failure code [DKA0L0] Boom Angle Sensor Dislocation ...................................................... 40-628
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor.................................. 40-630
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor............................................. 40-632
WA320-7 00-9
00 Index and foreword
Index
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B).......................................... 40-633
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A).......................................... 40-635
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B)............................................... 40-637
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ............................................. 40-640
Failure code [DPQ1KR] LIN Discon (Switch Panel) ............................................................. 40-642
Failure code [DPQ2KR] LIN Discon (LED Unit) ................................................................... 40-645
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ..................................................... 40-648
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) .............................................................. 40-651
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. .......................................... 40-653
Failure code [DV00KB] Ground Fault of Buzzer Output........................................................ 40-655
Failure code [DW26KA] Disconnection of Motor 2 Solenoid ................................................. 40-657
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid ................................................... 40-659
Failure code [DW26KY] Hot Short of Motor 2 Solenoid ........................................................ 40-661
Failure code [DW4BKA] Disconnection of Parking Brake Valve ............................................ 40-663
Failure code [DW4BKB] Ground Fault of Parking Brake Valve.............................................. 40-665
Failure code [DW4BKY] Hot Short of Parking Brake Valve ................................................... 40-667
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt).......................................... 40-668
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .................................... 40-670
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt).......................................... 40-672
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ......................................... 40-673
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid........................................... 40-675
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ................................................ 40-677
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................... 40-678
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ........................................ 40-680
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ............................................. 40-682
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..................................... 40-684
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)....................................... 40-686
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ............................................ 40-688
Failure code [DX19KA] Disconnection of Motor 1 Solenoid .................................................. 40-689
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid.................................................... 40-691
Failure code [DX19KY] Hot Short of Motor 1 Solenoid ......................................................... 40-693
Failure code [DX20KA] Disconnection of Clutch Control Solenoid ........................................ 40-695
Failure code [DX20KB] Ground Fault of Clutch Control Solenoid .......................................... 40-697
Failure code [DX20KY] Hot Short of Clutch Control Solenoid ............................................... 40-699
Failure code [DXAWKA] Disconnection of HST Pump EPC Sol. ........................................... 40-701
Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol.............................................. 40-703
Failure code [DXAWKY] Hot Short of HST Pump EPC Sol. .................................................. 40-705
Failure code [DXH7KA] Disconnection of Reverse Solenoid ................................................ 40-707
Failure code [DXH7KB] Ground Fault of Reverse Solenoid .................................................. 40-709
Failure code [DXH7KY] Hot Short of Reverse Solenoid ....................................................... 40-711
Failure code [DXH8KA] Disconnection of Forward Solenoid................................................. 40-713
Failure code [DXH8KB] Ground Fault of Forward Solenoid .................................................. 40-715
Failure code [DXH8KY] Hot Short of Forward Solenoid........................................................ 40-717
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ....................................... 40-719
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)......................................... 40-721
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .............................................. 40-723
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................... 40-724
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)........................................ 40-726
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ............................................. 40-728
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal............................................... 40-729
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ........................................... 40-732
Failure code [J141N1] Steering Pump Over Run................................................................. 40-734
Failure code [LA00L3] Failure of Fan Reverse .................................................................... 40-735
Failure code [M100N1] HST Pump Over Run ..................................................................... 40-736
Failure code [M400N1] HST Motor 1 Over Run ................................................................... 40-737
Troubleshooting of electrical system (E-mode) .......................................................................... 40-738
E-1 Engine does not start.................................................................................................. 40-738
E-2 Manual preheating system does not work..................................................................... 40-745
E-3 Automatic preheating system does not work................................................................. 40-748
00-10 WA320-7
00 Index and foreword
Index
E-4 While preheating is working, preheating monitor does not light up .................................. 40-750
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .................. 40-752
E-6 LCD unit on machine monitor displays nothing.............................................................. 40-755
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers).............................................................................................................. 40-757
E-8 LCD on machine monitor does not display properly ....................................................... 40-759
E-9 Meter unit display on machine monitor is abnormal ....................................................... 40-761
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................................. 40-764
E-11 Caution LED on machine monitor is abnormal............................................................. 40-767
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate
properly ............................................................................................................. 40-769
E-13 Two switches operation of switch panel on machine monitor does not function .............. 40-771
E-14 Switch panel buzzer of machine monitor is abnormal................................................... 40-774
E-15 Rearview monitor does not light up or backlight flickers ............................................... 40-776
E-16 Rearview monitor images are not displayed clearly ..................................................... 40-779
E-17 Rearview monitor brightness cannot be adjusted ........................................................ 40-782
E-18 Night lighting lamp of rearview monitor is abnormal ..................................................... 40-785
E-19 Some items of gauges and caution lamps on machine monitor are not displayed
properly ............................................................................................................. 40-787
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position.............................................................................................................. 40-788
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
light ................................................................................................................... 40-792
E-22 Air cleaner clogging indicator lamp does not light ........................................................ 40-794
E-23 Radiator coolant level caution lamp does not light ....................................................... 40-796
E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature
caution lamp does not light .................................................................................. 40-798
E-25 When brake pedal (inching pedal) is depressed, inching function does not work (travel
speed or traction force does not lower), or while not depressed, inching function
operates ............................................................................................................ 40-799
E-26 Fuel level gauge does not indicate correct level .......................................................... 40-801
E-27 Seat belt caution lamp indication is abnormal.............................................................. 40-803
E-28 Horn does not sound ................................................................................................ 40-804
E-29 Horn does not stop sounding..................................................................................... 40-807
E-30 Alarm buzzer does not sound .................................................................................... 40-809
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................ 40-811
E-32 When emergency HST pump drive switch is operated, emergency HST pump does not
work or when emergency HST pump drive switch is not operated, emergency HST
pump works ....................................................................................................... 40-812
E-33 Setting does not change while operating traction control switch.................................... 40-814
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake
is released and FR drive is operated..................................................................... 40-816
E-35 Remote positioner does not work or cannot be released .............................................. 40-819
E-36 Bucket positioner does not work or cannot be released................................................ 40-821
E-37 Direction selector (FNR) switch mode is not selected or not released............................ 40-824
E-38 PZ auto tilt-in does not work ...................................................................................... 40-826
E-39 Tracktion level does not display MAX when max traction switch is turned ON ................ 40-829
E-40 ECSS function cannot be selected or cannot be released ............................................ 40-831
E-41 None of headlamp, clearance lamp, and tail lamp lights............................................... 40-833
E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out ..................... 40-835
E-43 Both High and Low beams of headlamp do not light up or go out .................................. 40-839
E-44 Low beam of headlamp does not light up or go out ...................................................... 40-843
E-45 High beam of headlamp does not light up or go out ..................................................... 40-845
E-46 Front working lamp does not light up or go out ............................................................ 40-847
E-47 Rear working lamp does not light up or go out............................................................. 40-851
E-48 All of turn signal lamps and hazard lamps do not flash or go out ................................... 40-855
E-49 Turn signal lamps do not flash or go out ..................................................................... 40-858
E-50 Hazard lamp does not flash or go out ......................................................................... 40-861
E-51 Brake lamp does not light or stays lighted ................................................................... 40-864
WA320-7 00-11
00 Index and foreword
Index
E-52 Backup lamp does not light up or does not go out........................................................ 40-867
E-53 Backup buzzer does not sound or continues to sound ................................................. 40-870
E-54 Front wiper does not operate..................................................................................... 40-872
E-55 Rear wiper does not operate ..................................................................................... 40-875
E-56 Window washer does not operate .............................................................................. 40-877
E-57 KOMTRAX system does not operate normally ............................................................ 40-880
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-882
Information described in troubleshooting table (H-mode) ..................................................... 40-882
System chart of hydraulic and mechanical systems............................................................. 40-883
Failure mode and cause table ........................................................................................... 40-885
H-1 Machine does not travel forward or backward ............................................................... 40-891
H-2 Machine does not travel forward (Machine travels backward normally) ........................... 40-894
H-3 Machine does not travel backward (Machine travels forward normally) ........................... 40-895
H-4 Machine does not travel forward or backward fast......................................................... 40-896
H-5 Machine does not travel forward fast (Machine travel backward fast) .............................. 40-900
H-6 Machine does not travel backward fast (Machine travel forward fast) .............................. 40-901
H-7 Machine lacks power neither when traveling forward nor backward ................................ 40-902
H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling
backward) .......................................................................................................... 40-905
H-9 Machine lacks power when traveling backward (Machine have sufficient power when
traveling forward)................................................................................................ 40-906
H-10 Engine stalls during travel or engine speed drops significantly ..................................... 40-907
H-11 Steering wheel is too heavy to turn............................................................................. 40-908
H-12 Steering wheel is heavy to turn.................................................................................. 40-910
H-13 Machine sways or large shocks are made while machine turns .................................... 40-911
H-14 Machine unintentionally turns when machine travels ................................................... 40-912
H-15 Wheel brakes do not work or are weak....................................................................... 40-913
H-16 Wheel brakes are not released or drag....................................................................... 40-914
H-17 Parking brake does not work or it is weak ................................................................... 40-915
H-18 Parking brake is not released or drags. ...................................................................... 40-916
H-19 Boom does not rise .................................................................................................. 40-917
H-20 Boom moves slow or boom lacks lifting force .............................................................. 40-919
H-21 Rising boom slows down at certain height .................................................................. 40-921
H-22 Lift cylinders do not serve to hold bucket (bucket rises off ground) ................................ 40-922
H-23 Hydraulic drift of boom is large .................................................................................. 40-923
H-24 Boom moves up and down during operation ............................................................... 40-924
H-25 Bucket does not tilt back ........................................................................................... 40-925
H-26 Bucket moves slow or lacks tilt force .......................................................................... 40-927
H-27 Bucket decelerates during tilt-back operation.............................................................. 40-929
H-28 Bucket cylinder does not hold bucket on ground ......................................................... 40-930
H-29 Hydraulic drift of bucket is large ................................................................................. 40-931
H-30 Bucket tilts back and forth during carrying load ........................................................... 40-932
H-31 Boom and bucket control levers do not move smoothly and are heavy to move ............. 40-933
H-32 Operating work equipment causes engine speed to lower significantly or engine to
stall ................................................................................................................... 40-934
H-33 Large shocks are made when work equipment starts to move and stops ....................... 40-935
H-34 When certain work equipment is relieved hydraulically, other work equipment
moves ............................................................................................................... 40-936
H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces................... 40-937
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) .................................... 40-938
H-37 Unusual noise is heard from around fan ..................................................................... 40-940
Troubleshooting of engine (S-mode)......................................................................................... 40-941
Information described in troubleshooting table (S mode)...................................................... 40-941
S-1 Engine does not crank when starting switch is turned to START position......................... 40-942
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-943
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-944
S-4 Engine startability is poor............................................................................................ 40-945
S-5 Engine does not pick up smoothly ............................................................................... 40-947
00-12 WA320-7
00 Index and foreword
Index
S-6 Engine stops during operation ..................................................................................... 40-949
S-7 Engine runs rough or is unstable ................................................................................. 40-951
S-8 Engine lacks power .................................................................................................... 40-952
S-9 KDPF gets clogged in a short time............................................................................... 40-954
S-10 Engine oil consumption is excessive .......................................................................... 40-956
S-11 Engine oil becomes contaminated early...................................................................... 40-957
S-12 Fuel consumption is excessive .................................................................................. 40-958
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-959
S-14 Oil pressure drops.................................................................................................... 40-960
S-15 Fuel mixes into engine oil.......................................................................................... 40-961
S-16 Water mixes into engine oil (milky) ............................................................................. 40-962
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-963
S-18 Unusual noise is heard ............................................................................................. 40-964
S-19 Vibration is excessive ............................................................................................... 40-965
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-967
S-21 Active regeneration is executed frequently ................................................................. 40-968
S-22 Active regeneration takes time................................................................................... 40-969
S-23 White smoke is exhausted during active regeneration ................................................. 40-970
50 Disassembly and assembly ...........................................................................................................50-1
Table of contents ........................................................................................................................50-2
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual .......................................................................................................50-4
Coating materials list ............................................................................................................50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system........................................................................................................ 50-28
Removal and installation of supply pump assembly............................................................... 50-28
Removal and installation of injector assembly....................................................................... 50-31
Removal and installation of cylinder head assembly.............................................................. 50-40
Removal and installation of engine hood assembly ............................................................... 50-53
Removal and installation of radiator core assembly ............................................................... 50-55
Removal and installation of aftercooler................................................................................. 50-57
Removal and installation of hydraulic oil cooler ..................................................................... 50-58
Removal and installation of engine assembly ....................................................................... 50-59
Removal and installation of engine front oil seal .................................................................... 50-67
Removal and installation of engine rear oil seal..................................................................... 50-70
Removal and installation of cooling fan and fan motor assembly ............................................ 50-73
Removal and installation of KDPF assembly......................................................................... 50-75
Disassembly and assembly of KDPF assembly .................................................................... 50-78
Removal and installation of KCCV assembly ........................................................................ 50-87
Removal and installation of air cleaner assembly .................................................................. 50-88
Removal and installation of KVGT assembly......................................................................... 50-89
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly........................ 50-92
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly....................... 50-94
Removal and installation of alternator belt ............................................................................ 50-96
Removal and installation of fuel tank assembly ..................................................................... 50-97
Power train............................................................................................................................. 50-100
Removal and installation of transfer assembly .................................................................... 50-100
Disassembly and assembly of transfer assembly ................................................................ 50-104
Removal and installation of front axle assembly .................................................................. 50-135
Removal and installation of rear axle assembly................................................................... 50-137
Disassembly and assembly of axle housing assembly......................................................... 50-140
Disassembly and assembly of differential assembly ............................................................ 50-152
Undercarriage and frame......................................................................................................... 50-174
Removal and installation of center hinge pin ....................................................................... 50-174
Removal and installation of counterweight assembly........................................................... 50-183
Hydraulic system .................................................................................................................... 50-187
Removal and installation of hydraulic tank assembly ........................................................... 50-187
Removal and installation of control valve assembly ............................................................. 50-191
WA320-7 00-13
00 Index and foreword
Index
Disassembly and assembly of control valve assembly......................................................... 50-195
Removal and installation of hydraulic pump assembly ......................................................... 50-198
Removal and installation of HST motor1 assembly.............................................................. 50-203
Removal and installation of HST motor2 assembly.............................................................. 50-205
Disassembly and assembly of hydraulic cylinder assembly.................................................. 50-207
Work equipment ..................................................................................................................... 50-214
Removal and installation of work equipment assembly ........................................................ 50-214
Cab and its attachments.......................................................................................................... 50-220
Removal and installation of operator's cab and floor frame assembly.................................... 50-220
Removal and installation of operator's cab glass (adhered glass) ......................................... 50-225
Removal and installation of operator's seat assembly.......................................................... 50-233
Removal and installation of seat belt.................................................................................. 50-235
Removal and installation of air conditioner unit assembly..................................................... 50-236
Removal and installation of air conditioner compressor ....................................................... 50-241
Removal and installation of air conditioner condenser ......................................................... 50-243
Electrical system .................................................................................................................... 50-245
Removal and installation of machine monitor assembly ....................................................... 50-245
Removal and installation of engine controller assembly ....................................................... 50-247
Removal and installation of HST controller assembly........................................................... 50-249
Removal and installation of air conditioner controller assembly ............................................ 50-251
Removal and installation of monitor controller assembly ...................................................... 50-252
Removal and installation of mass air flow and temperature sensor ....................................... 50-254
Removal and installation of KOMTRAX terminal assembly .................................................. 50-255
60 Maintenance standard...................................................................................................................60-1
Table of contents ........................................................................................................................60-2
Engine and cooling system..........................................................................................................60-3
Engine related parts .............................................................................................................60-3
Cooling fan motor.................................................................................................................60-4
Power train.................................................................................................................................60-6
Damper...............................................................................................................................60-6
Transfer ..............................................................................................................................60-7
Drive shaft......................................................................................................................... 60-14
Axle .................................................................................................................................. 60-15
Differential......................................................................................................................... 60-17
Limited slip differential ........................................................................................................ 60-21
Final drive ......................................................................................................................... 60-23
Steering system........................................................................................................................ 60-25
Steering column................................................................................................................. 60-25
Priority valve...................................................................................................................... 60-26
Emergency steering valve................................................................................................... 60-27
Steering cylinder ................................................................................................................ 60-28
Brake system ........................................................................................................................... 60-30
Brake accumulator charge valve.......................................................................................... 60-30
Slack adjuster.................................................................................................................... 60-31
Brake................................................................................................................................ 60-32
Parking brake .................................................................................................................... 60-34
Parking brake solenoid valve ..............................................................................................60-35
Undercarriage and frame........................................................................................................... 60-36
Axle mount ........................................................................................................................ 60-36
Center hinge pin ................................................................................................................ 60-38
Hydraulic system ...................................................................................................................... 60-41
Hydraulic tank.................................................................................................................... 60-41
Double type gear pump ...................................................................................................... 60-42
Steering and work equipment pump..................................................................................... 60-43
Control valve ..................................................................................................................... 60-47
Self-pressure reducing valve............................................................................................... 60-60
Work equipment PPC valve ................................................................................................ 60-62
Work equipment lock solenoid valve .................................................................................... 60-64
Work equipment ....................................................................................................................... 60-65
00-14 WA320-7
00 Index and foreword
Index
Work equipment linkage ..................................................................................................... 60-65
Bucket .............................................................................................................................. 60-69
Work equipment cylinder .................................................................................................... 60-71
Cab and its attachments............................................................................................................ 60-72
Cab mount ........................................................................................................................ 60-72
Electrical system ...................................................................................................................... 60-73
Bucket positioner ............................................................................................................... 60-73
Fork positioner................................................................................................................... 60-74
Remote boom positioner..................................................................................................... 60-75
80 Appendix......................................................................................................................................80-1
Table of contents ........................................................................................................................80-2
Air conditioner components .........................................................................................................80-3
Precautions for refrigerant.....................................................................................................80-3
Air conditioner component ....................................................................................................80-4
Configuration and function of refrigeration cycle......................................................................80-6
Outline of refrigeration cycle..................................................................................................80-7
Air conditioner unit ...............................................................................................................80-9
Dual pressure switch .......................................................................................................... 80-14
Air conditioner controller .....................................................................................................80-15
Compressor....................................................................................................................... 80-16
Condenser ........................................................................................................................ 80-17
Receiver drier .................................................................................................................... 80-18
Sunlight sensor.................................................................................................................. 80-20
Outer temperature sensor (outside air temperature sensor) ................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-27
Parts and connectors layout................................................................................................80-30
Testing with self-diagnosis function ...................................................................................... 80-35
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-36
Testing temperature control system ..................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-40
Testing FRESH/RECIRC air changeover.............................................................................. 80-42
Testing evaporator temperature sensor ................................................................................ 80-44
Testing relays .................................................................................................................... 80-46
Troubleshooting chart 1 ...................................................................................................... 80-48
Troubleshooting chart 2 ...................................................................................................... 80-49
Information in troubleshooting table ..................................................................................... 80-51
Failure code list related to air conditioner.............................................................................. 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-55
Failure code [879BKA] A/C Outer Sensor Open Circuit.......................................................... 80-57
Failure code [879BKB] A/C Outer Sensor Short Circuit.......................................................... 80-59
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-61
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-63
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................................................ 80-65
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-67
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-70
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does
not operate).......................................................................................................... 80-73
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-76
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-79
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-82
Troubleshooting with gauge pressure................................................................................... 80-84
Connection of service tool................................................................................................... 80-87
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit................................................................................................................... 80-89
WA320-7 00-15
00 Index and foreword
Index
Handling of compressor oil.................................................................................................. 80-91
90 Diagrams and drawings.................................................................................................................90-1
Table of contents ........................................................................................................................90-2
Hydraulic circuit diagram .............................................................................................................90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram.......................................................................................................90-7
Electric circuit diagram ................................................................................................................90-9
Symbols in electric circuit diagram.........................................................................................90-9
Electrical circuit diagram of machine body ............................................................................ 90-13
Electrical circuit diagram of floor .......................................................................................... 90-23
Index.................................................................................................................................................................... 1
00-16 WA320-7
00 Index and foreword
Foreword, safety and general information
Foreword, safety and general information
(ALL-0370-001-A-00-A)
Important safety notice
(ALL-1120-012-A-01-A)
(Rev. 2014/08)
•Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
•The symbol mark kis used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
Safety points
•Good arrangement
•Correct work clothes
•Observance of work standard
•Practice of making and checking signals
•Prohibition of operation and handling by
unlicensed workers
•Safety check before starting work
•Wearing protective goggles (for cleaning or
grinding work)
•Wearing shielding goggles and protectors (for
welding work)
•Good physical condition and preparation
•Precautions against work which you are not
used to or you are used to too much
General precautions
kk Inappropriate handling causes an extreme
danger. Read and understand what is
described in the operation and maintenance
manual before operating the machine. Read
and understand what is described in this
manual before starting the work.
•Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For
the locations of the safety labels and detailed
explanation of precautions, see the operation
and maintenance manual.
•Locate a place in the repair workshop to keep
the tools and removed parts. Always keep the
tools and parts in their correct places. Always
keep the work area clean and make sure that
there is no dirt, water or oil on the floor. Smoke
only in the areas provided for smoking. Never
smoke while working.
•When performing any work, always wear the
safety shoes and helmet. Do not wear loose
work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when
hitting parts with a hammer.
2. Always wear the protective eyeglasses when
grinding parts with a grinder, etc.
•When performing any work with 2 or more
workers, always agree on the working procedure
before starting. While working, always keep
conversations of the work between your fellow
workers and your self on any step of the work.
During the work, hang the warning tag of
"UNDER WORKING" in the operator's
compartment.
•Only qualified workers must perform the work
and operation which require license or
qualification.
•Keep the tools in good condition. And learn the
correct way to use the tools, and use the proper
ones among them. Before starting the work,
thoroughly check the tools, lift truck, service
vehicle, etc.
•If welding repairs is required, always have a
trained and experienced welder with good
knowledge of welding perform the work. When
performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
•Before starting work, warm up your body
thoroughly to start work under good condition.
•Avoid continuing work for long hours and take
rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
place.
Preparation
•Before adding oil or making any repairs, place
the machine on a firm and level ground, and
apply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
•Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it is
not possible to lower the equipment to the
ground, insert the lock pin or use blocks to
prevent the work equipment from falling. And be
sure to lock all the work equipment control levers
and hang a warning tag on them.
•When performing the disassembling or
assembling work, support the machine securely
with blocks, jacks, or stands before starting the
work.
•Remove all of mud and oil from the steps or
other places used to get on and off the machine
completely. Always use the handrails, ladders of
steps when getting on or off the machine. Never
WA320-7 00-17
00 Index and foreword
Foreword, safety and general information
jump on or off the machine. When the scaffold is
not provided, use steps or stepladder to secure
your footing.
Precautions during work
•For the machine equipped with the battery
disconnect switch, check that the system
operating lamp is turned off before starting the
work. Then, turn the battery disconnect switch to
OFF (Q) position and remove the switch key. For
the machine not equipped with the battery
disconnect switch, remove the cable from the
battery before starting the work. Be sure to
remove the negative end (-) of the battery cable
first.
•Release the remaining pressure in the circuits
completely before the work when the parts in the
circuits of oil, fuel, coolant and air are
disconnected or removed. When the cap of the
oil filter, drain plug or oil pressure pickup plug is
removed, loose them slowly to prevent the oil
from spurting out.
•When removing or installing the checking plug or
the piping in the fuel circuit, wait 30 seconds or
longer after the engine is shut down and start
the work after the remaining pressure is
released from the fuel circuit.
•Immediately after the engine is shut down, the
coolant and oil in the circuits are hot. Be careful
not to get scalded by the hot coolant and oil.
Start the work after checking that the coolant
and oil are cooled down sufficiently.
•Start the work after the engine is shut down. Be
sure to shut down the engine when working on
or around the rotating parts in particular. When
checking the machine without shutting down the
engine (measuring oil pressure, rotational speed,
oil or coolant temperature), take extreme care
not to get caught in the rotating parts or the
working equipment.
•The hoist or crane must be used to sling the
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the
slings with ample capacity and install them to
the proper places. Operate the hoist or crane
slowly to prevent the component from hitting any
other part. Do not work with any part still raised
by the hoist or crane.
•When removing the part which is under internal
pressure or reaction force of the spring, always
leave 2 bolts in diagonal positions. Loosen those
2 bolts gradually and alternately and release the
pressure, then, remove the part.
•When removing the part, be careful not to break
or damage the electrical wiring. The damaged
wiring may cause electrical fires.
•When removing piping, prevent the fuel or oil
from spilling out. If any fuel or oil drips onto the
floor, wipe it off immediately. Fuel or oil on the
floor can cause you to slip and can even cause
fires.
•As a general rule, do not use gasoline to wash
parts. Do not use gasoline to clean the electrical
parts, in particular.
•Reinstall the parts removed to their original
places. Replace the damaged parts and the
parts which must not be used with new ones.
When installing the hoses and wiring harnesses,
be careful that they are not damaged by
contacting with other parts when the machine is
operated.
•When connecting the high pressure hoses and
tubes, make sure that they are not twisted. The
damaged high pressure hoses and tubes are
very dangerous when they are installed. So, be
extremely careful when connecting the high
pressure pipings. In addition, check that their
connections are correct.
•When assembling or installing the parts, be sure
to tighten the bolts to the specified torque. When
installing the protective parts such as guards, or
the parts which vibrate violently or rotate at high
speeds, be sure to check that they are installed
correctly.
•When aligning 2 holes, never insert your fingers
or hand into the holes. Align the holes with care
so that your fingers are not caught in the hole.
•When measuring hydraulic pressure, check that
the measuring tools are correctly installed.
•Pay attention to safety when removing and
installing the tracks of the track type machines.
When removing the track, it separates suddenly.
The workers should not stand at either end of
the track.
•If the engine is operated for a long time in a
closed place which is not ventilated well, you
may suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate the
place well.
Precautions for slinging work and making
signals
•Only one appointed worker must make signals
and co-worker must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at the place
where the signaler is well seen from the
operator's seat and where the signaler can see
the working condition easily. The signaler must
always stand in front of the load and guide the
operator safely.
1. Do not stand under the load.
2. Do not step on the load.
•Check the slings before starting sling work.
•Keep putting on the gloves during sling work.
(Put on the leather gloves, if available.)
00-18 WA320-7
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