VENBM42500
WHEEL LOADER
WA470 -7 SERIAL NUMBERS
H52051 and up 10001 and up
SHOP MANUAL
WHEEL LOADER WA470-7 Model
Serial Number
WA470-7
H52051 and up 10001 and up
00 Index and foreword 1 00 Index and foreword
WA470-7
00-1
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 ................................................................................... 00-18 Important safety notice ....................................................................................................... 00-18 How to read the shop manual.............................................................................................. 00-25 Explanation of terms for maintenance standard .................................................................... 00-27 Handling equipment of fuel system devices .......................................................................... 00-29 Handling of intake system parts........................................................................................... 00-30 Handling of hydraulic equipment.......................................................................................... 00-31 Method of disconnecting and connecting of push-pull type coupler ......................................... 00-33 Handling of electrical equipment.......................................................................................... 00-36 How to read electric wire code............................................................................................. 00-44 Precautions when performing operation ............................................................................... 00-47 Practical use of KOMTRAX ................................................................................................. 00-51 Standard tightening torque table.......................................................................................... 00-52 List of abbreviation ............................................................................................................. 00-56 Conversion table ................................................................................................................ 00-61 01 Specification................................................................................................................................. 01-1 Table of contents ........................................................................................................................ 01-2 Specifications............................................................................................................................. 01-3 Specification drawing ........................................................................................................... 01-3 Specifications ...................................................................................................................... 01-5 Weight table ...................................................................................................................... 01-11 Table of fuel, coolant, and lubricants .................................................................................... 01-13 10 Structure and function ................................................................................................................... 10-1 Table of contents ........................................................................................................................ 10-2 Engine and cooling system .......................................................................................................... 10-4 Engine related parts ............................................................................................................. 10-4 KVGT.................................................................................................................................. 10-6 EGR system piping drawing ................................................................................................ 10-12 EGR system circuit diagram ................................................................................................ 10-14 EGR valve......................................................................................................................... 10-15 EGR cooler........................................................................................................................ 10-17 KCCV layout drawing ......................................................................................................... 10-19 KCCV ventilator ................................................................................................................. 10-21 KDPF................................................................................................................................ 10-23 Cooling system .................................................................................................................. 10-27 Cooling fan pump ............................................................................................................... 10-30 Cooling fan motor............................................................................................................... 10-39 Power train............................................................................................................................... 10-46 Power train system............................................................................................................. 10-46 Drive shaft ......................................................................................................................... 10-49 Power train piping drawing .................................................................................................. 10-50 Transmission control .......................................................................................................... 10-51 Torque converter ................................................................................................................ 10-54 Transmission ..................................................................................................................... 10-59 Transmission control valve.................................................................................................. 10-78 Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV .......................................... 10-81 3rd, 4th clutch ECMV.......................................................................................................... 10-88 Lockup clutch ECMV .......................................................................................................... 10-95 Main relief and torque converter relief valve.......................................................................... 10-99 Axle ................................................................................................................................ 10-101 Differential ....................................................................................................................... 10-103 Final drive ....................................................................................................................... 10-113 Steering system...................................................................................................................... 10-115 Layout of steering parts .................................................................................................... 10-115 Steering column............................................................................................................... 10-116
00-2
WA470-7
00 Index and foreword Index
Steering pump .................................................................................................................................................. 10-117 Steering valve.................................................................................................................................................... 10-129 Orbit-roll valve .................................................................................................................................................. 10-143 Stop valve .......................................................................................................................................................... 10-149 Emergency steering motor ............................................................................................................................. 10-150 Emergency steering pump .............................................................................................................................. 10-151 Brake system ............................................................................................................................................................. 10-152 Layout of brake parts....................................................................................................................................... 10-152 Charge valve ..................................................................................................................................................... 10-154 Brake valve ........................................................................................................................................................ 10-160 Slack adjuster ..................................................................................................................................................... 10-164 Accumulator (for brake) .................................................................................................................................. 10-167 Brake ................................................................................................................................................................... 10-168 Parking brake control ...................................................................................................................................... 10-171 Parking brake .................................................................................................................................................... 10-172 Parking brake solenoid valve .......................................................................................................................... 10-173 Parking brake emergency release valve........................................................................................................ 10-176 Undercarriage and frame......................................................................................................................................... 10-177 Axle mount and center hinge pin.................................................................................................................. 10-177 Tire ...................................................................................................................................................................... 10-178 Hydraulic system ...................................................................................................................................................... 10-180 Hydraulic component layout .......................................................................................................................... 10-180 Work equipment control ................................................................................................................................. 10-182 Hydraulic tank................................................................................................................................................... 10-183 Double type gear pump ................................................................................................................................. 10-186 Work equipment pump.................................................................................................................................... 10-187 Control valve ..................................................................................................................................................... 10-208 CLSS .................................................................................................................................................................... 10-217 Hydraulic circuit diagram and names of valves........................................................................................... 10-221 Accumulator charge valve............................................................................................................................... 10-232 Work equipment lock solenoid valve ........................................................................................................... 10-236 Accumulator (for PPC circuit) ......................................................................................................................... 10-237 Accumulator (for ECSS) ................................................................................................................................... 10-238 Work equipment ...................................................................................................................................................... 10-239 Work equipment linkage ................................................................................................................................ 10-239 Bucket ................................................................................................................................................................ 10-240 Bucket positioner and boom positioner....................................................................................................... 10-241 Cab and its attachments .......................................................................................................................................... 10-242 ROPS cab ........................................................................................................................................................... 10-242 Electrical system ....................................................................................................................................................... 10-243 Engine control system ..................................................................................................................................... 10-243 Preheating system ........................................................................................................................................... 10-245 Engine power mode selector circuit ............................................................................................................. 10-247 Engine output limit function ......................................................................................................................... 10-248 Automatic warm-up function......................................................................................................................... 10-249 Parking brake control system ........................................................................................................................ 10-250 System operating lamp function................................................................................................................... 10-252 Battery disconnect switch function ............................................................................................................... 10-254 Transmission controller system ...................................................................................................................... 10-256 Work equipment control system.................................................................................................................... 10-277 Machine monitor system ................................................................................................................................. 10-293 Rear view monitor system............................................................................................................................... 10-317 KOMTRAX system ............................................................................................................................................. 10-320 System component parts ................................................................................................................................ 10-323 Sensor ................................................................................................................................................................ 10-350 Central lubrication system (CLS)............................................................................................................................. 10-379 20 Standard value tables........................................................................................................................................................ 20-1 Table of contents ........................................................................................................................................................... 20-2 Standard service value table........................................................................................................................................ 20-3 Standard value table for engine ......................................................................................................................... 20-3 WA470-7
00-3
00 Index and foreword Index
Standard value table for machine .......................................................................................... 20-5 Standard value table for electrical system............................................................................. 20-18 30 Testing and adjusting .................................................................................................................... 30-1 Table of contents ........................................................................................................................ 30-2 General information on testing and adjusting................................................................................. 30-4 Tools for testing and adjusting ............................................................................................... 30-4 Sketch of tools for testing and adjusting ................................................................................. 30-8 Engine and cooling system ........................................................................................................ 30-10 Testing engine speed ......................................................................................................... 30-10 Testing boost pressure ....................................................................................................... 30-12 Testing exhaust gas color ................................................................................................... 30-14 Testing and adjusting valve clearance .................................................................................. 30-16 Testing compression pressure............................................................................................. 30-18 Testing blowby pressure ..................................................................................................... 30-22 Testing engine oil pressure ................................................................................................. 30-24 Testing EGR valve and KVGT oil pressures .......................................................................... 30-25 Testing fuel pressure .......................................................................................................... 30-26 Testing fuel return rate and leakage ..................................................................................... 30-27 Bleeding air from fuel system .............................................................................................. 30-31 Testing fuel circuit for leakage ............................................................................................. 30-33 Handling cylinder cutout mode operation.............................................................................. 30-34 Handling no injection cranking operation .............................................................................. 30-35 Testing of KDPF and muffler stack for looseness and damage ............................................... 30-36 Testing of installed condition of cylinder head and manifolds .................................................. 30-37 Testing engine piping for damage and looseness .................................................................. 30-38 Testing and adjusting air conditioner compressor belt tension ................................................ 30-39 Testing and adjusting alternator belt tension ......................................................................... 30-41 Procedures for cleaning fuel doser....................................................................................... 30-43 Writing compensation values at replacement of injector and engine controller ......................... 30-46 Power train............................................................................................................................... 30-50 Adjusting transmission output speed sensor ......................................................................... 30-50 Adjusting transmission input speed sensor ........................................................................... 30-51 Flushing procedure for torque converter and transmission hydraulic circuit.............................. 30-52 Retrieval of disabled machine due to transmission valve failure.............................................. 30-54 Testing oil leakage from axle final drive ................................................................................ 30-56 Testing drive shaft for looseness, backlash, and damage....................................................... 30-57 Testing and adjusting power train oil pressure....................................................................... 30-58 Steering system........................................................................................................................ 30-73 Testing directional lever ...................................................................................................... 30-73 Testing steering wheel ........................................................................................................ 30-74 Testing work equipment control lever ................................................................................... 30-76 Testing and adjusting steering circuit oil pressure.................................................................. 30-78 Bleeding air from steering cylinder circuit.............................................................................. 30-81 Testing and adjusting steering stopper valve......................................................................... 30-82 Brake system ........................................................................................................................... 30-83 Testing brake pedal ............................................................................................................ 30-83 Testing and adjusting brake pedal linkage ............................................................................ 30-84 Testing braking performance ............................................................................................... 30-85 Testing and adjusting of accumulator charge pressure........................................................... 30-86 Testing of brake accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas................................................................................ 30-88 Testing wheel brake oil pressure.......................................................................................... 30-92 Testing lowering of wheel brake pressure ............................................................................. 30-94 Testing wear of wheel brake disc ......................................................................................... 30-96 Bleeding air from wheel brake circuit.................................................................................... 30-97 Releasing remaining pressure in brake accumulator circuit .................................................... 30-99 Testing parking brake performance .................................................................................... 30-100 Testing parking brake oil pressure ..................................................................................... 30-101 Testing wear of parking brake disc ..................................................................................... 30-102
00-4
WA470-7
This is the sample of the manual Click on the download link for complete manual
Download Link
00 Index and foreword Index
Method of releasing parking brake manually ....................................................................... 30-103 Hydraulic system .................................................................................................................... 30-105 Testing fan speed............................................................................................................. 30-105 Testing fan pump circuit oil pressure .................................................................................. 30-106 Bleeding air from hydraulic fan circuit ................................................................................. 30-108 Testing and adjusting work equipment EPC oil pressure ...................................................... 30-110 Testing and adjusting work equipment oil pressure.............................................................. 30-113 Bleeding air from work equipment circuit ............................................................................ 30-117 Releasing remaining pressure from work equipment circuit .................................................. 30-118 Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ................................................................................................ 30-119 Work equipment ..................................................................................................................... 30-123 Testing and adjusting bucket position detection lever........................................................... 30-123 Testing and adjusting boom position detection lever ............................................................ 30-124 Electrical system .................................................................................................................... 30-125 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor .............................................................................................................. 30-125 Special functions of machine monitor ................................................................................. 30-127 Adjusting rearview camera angle ....................................................................................... 30-216 Handling voltage circuit of engine controller........................................................................ 30-217 Handling battery disconnect switch .................................................................................... 30-218 Testing diodes ................................................................................................................. 30-219 Pm clinic ................................................................................................................................ 30-220 Pm Clinic service ............................................................................................................. 30-220 Check sheet .................................................................................................................... 30-221 40 Troubleshooting............................................................................................................................ 40-1 Table of contents ........................................................................................................................ 40-2 General information on troubleshooting ...................................................................................... 40-11 Troubleshooting points ....................................................................................................... 40-11 Sequence of events in troubleshooting................................................................................. 40-13 Check before troubleshooting.............................................................................................. 40-15 Inspection procedure before troubleshooting ........................................................................ 40-17 Preparation work for troubleshooting of electrical system....................................................... 40-34 Classification and procedures for troubleshooting ................................................................. 40-40 Symptom and troubleshooting numbers ............................................................................... 40-43 Information in troubleshooting table ..................................................................................... 40-46 Connector list and layout .................................................................................................... 40-48 Connector contact identification........................................................................................... 40-62 T-branch box and T-branch adapter table ............................................................................. 40-98 Fuse location table ........................................................................................................... 40-104 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-107 Precautions on troubleshooting of machine monitor ............................................................ 40-110 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit .................................................................................................................... 40-112 Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors)............................................................................................................. 40-117 Fabrication of short-circuit connector (for CA1883 and CA3135)........................................... 40-118 Failure codes table........................................................................................................... 40-119 Troubleshooting by failure code (Display of code) ...................................................................... 40-133 Failure code [1500L0] Double Engagement of T/M Clutches ................................................ 40-133 Failure code [15SAL1] Release Trouble of ECMV (Forward) ................................................ 40-134 Failure code [15SALH] Malfunction of ECMV (Forward)....................................................... 40-136 Failure code [15SBL1] Release Trouble of ECMV (Reverse)................................................ 40-138 Failure code [15SBLH] Malfunction of ECMV (Reverse) ...................................................... 40-140 Failure code [15SEL1] Release Trouble of ECMV (1st)........................................................ 40-142 Failure code [15SELH] Malfunction of ECMV (1st) .............................................................. 40-144 Failure code [15SFL1] Release Trouble of ECMV (2nd)....................................................... 40-146 Failure code [15SFLH] Malfunction of ECMV (2nd) ............................................................. 40-148 Failure code [15SGL1] Release Trouble of ECMV (3rd) ....................................................... 40-150 WA470-7
00-5
00 Index and foreword Index
Failure code [15SGLH] Malfunction of ECMV (3rd).............................................................. 40-152 Failure code [15SHL1] Release Trouble of ECMV (4th) ....................................................... 40-154 Failure code [15SHLH] Malfunction of ECMV (4th) .............................................................. 40-156 Failure code [2F00MA] Failure of Parking Brake Circuit ....................................................... 40-158 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-162 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-164 Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-166 Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-167 Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-168 Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-169 Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-170 Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-171 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-172 Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-173 Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-174 Failure code [989A00] Engine Overrun Prevention Activated ............................................... 40-175 Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-176 Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-177 Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-178 Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-179 Failure code [A1U0N4] HC Desorb Request 2 .................................................................... 40-181 Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-183 Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-185 Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-186 Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-188 Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-189 Failure code [B@CENS] T/C Oil Temp. Overheat................................................................ 40-191 Failure code [B@HANS] HYD Oil Temp. Overheat .............................................................. 40-192 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-193 Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-194 Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-196 Failure code [CA131] Throttle Sensor High Error................................................................. 40-198 Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-200 Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-202 Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-204 Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-206 Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-208 Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-210 Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-212 Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-214 Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-216 Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-218 Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-220 Failure code [CA234] Eng Overspeed ................................................................................ 40-221 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-222 Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-223 Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-224 Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-225 Failure code [CA273] PCV2 Short Error ............................................................................. 40-226 Failure code [CA274] PCV2 Open Error ............................................................................. 40-227 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-228 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-230 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-232 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-234 Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-236 Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-238 Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-240 Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-241 Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-242
00-6
WA470-7
00 Index and foreword Index
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-244 Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-246 Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-248 Failure code [CA431] Idle Validation Sw Error..................................................................... 40-249 Failure code [CA432] Idle Validation Process Error ............................................................. 40-252 Failure code [CA441] Battery Voltage Low Error ................................................................. 40-255 Failure code [CA442] Battery Voltage High Error................................................................. 40-257 Failure code [CA449] Rail Press Very High Error................................................................. 40-258 Failure code [CA451] Rail Press Sensor High Error............................................................. 40-259 Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-261 Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-263 Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-265 Failure code [CA553] Rail Press High Error ........................................................................ 40-267 Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-268 Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-269 Failure code [CA559] Rail Press Low Error......................................................................... 40-270 Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-274 Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-275 Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-277 Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-279 Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-281 Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-283 Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-284 Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-285 Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-286 Failure code [CA1117] Persistent Data Lost Error................................................................ 40-288 Failure code [CA1664] KDOC Malfunction.......................................................................... 40-289 Failure code [CA1691] Regeneration Ineffective ................................................................. 40-292 Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-295 Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-296 Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-298 Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-300 Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-302 Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-304 Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-306 Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-309 Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-312 Failure code [CA1923] Dosing Fuel Valve 1 High Error ........................................................ 40-317 Failure code [CA1924] Dosing Fuel Valve 1 Low Error......................................................... 40-319 Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-322 Failure code [CA1927] Dosing Fuel Press Sens High Error .................................................. 40-324 Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-326 Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-328 Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...................................................... 40-329 Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-331 Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-333 Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-335 Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-337 Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-339 Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-340 Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-342 Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-344 Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-346 Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-348 Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-350 Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-352 Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-353 Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-355 Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-357 WA470-7
00-7
00 Index and foreword Index
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-359 Failure code [CA2387] KVGT Servo Error .......................................................................... 40-361 Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-362 Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-364 Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-366 Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-368 Failure code [CA2732] Dosing Fuel Valve 2 High Error ........................................................ 40-371 Failure code [CA2733] Dosing Fuel Valve 2 Low Error......................................................... 40-373 Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-375 Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-377 Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...................................................... 40-378 Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-381 Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-386 Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-388 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-390 Failure code [CA3167] Fuel Doser Degradation .................................................................. 40-393 Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-396 Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-399 Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-402 Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-405 Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-409 Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-412 Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-415 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-418 Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-421 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-425 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-430 Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-433 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-437 Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-442 Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-446 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-449 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-454 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-456 Failure code [D150KA] Disconnection of Emerg. Steering Relay .......................................... 40-458 Failure code [D150KB] Ground Fault of Emerg. Steering Relay ............................................ 40-460 Failure code [D150KY] Hot Short of Emergency Steering Relay ........................................... 40-462 Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................................... 40-464 Failure code [D160KB] Ground Fault of Backup Lamp Relay Output..................................... 40-466 Failure code [D160KY] Hot Short of Backup Lamp Relay Output .......................................... 40-468 Failure code [D191KA] Disconnection of Neutral Output Relay............................................. 40-470 Failure code [D191KB] Ground Fault of Neutral Output Relay .............................................. 40-472 Failure code [D191KY] Hot Short of Neutral Output Relay.................................................... 40-474 Failure code [D192KA] Disconnection of ECSS Solenoid..................................................... 40-476 Failure code [D192KB] Ground Fault of ECSS Solenoid ...................................................... 40-478 Failure code [D192KY] Hot Short of ECSS Solenoid ........................................................... 40-479 Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-480 Failure code [D1E6KA] Disconnection of Parking Brake Relay ............................................. 40-482 Failure code [D1E6KB] Ground Fault of Parking Brake Relay............................................... 40-484 Failure code [D1E6KY] Hot Short of Parking Brake Relay .................................................... 40-486 Failure code [D5ZHKA] Failure of Key SW C Signal ............................................................ 40-488 Failure code [D5ZHKB] Key SW C Signal Short Circuit........................................................ 40-490 Failure code [D5ZHKZ] Failure of Key SW C Signal ............................................................ 40-492 Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-494 Failure code [D811MC] KOMTRAX Error............................................................................ 40-496 Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-497 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-498 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-500 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-502
00-8
WA470-7
00 Index and foreword Index
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-503 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-505 Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-506 Failure code [DAF0MC] Monitor Error ................................................................................ 40-507 Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-508 Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-510 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-511 Failure code [DAFGMC] GPS Module Error........................................................................ 40-513 Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-514 Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-516 Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-518 Failure code [DAQ0KK] Controller Power Source Low (T/M) ................................................ 40-519 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....................................... 40-522 Failure code [DAQ0MC] T/M Con Error .............................................................................. 40-523 Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .............................................. 40-524 Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ................................................. 40-526 Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay .......................................... 40-529 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .......................................... 40-531 Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ................................................ 40-532 Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ................................................ 40-534 Failure code [DAQQKR] CAN2 Discon (Transmission Con) ................................................. 40-536 Failure code [DAQRKR] CAN1 Discon (Transmission Con) ................................................. 40-537 Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ......................................... 40-538 Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-539 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-540 Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-541 Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-546 Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................... 40-551 Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ...................................... 40-553 Failure code [DB90MC] BBC Error..................................................................................... 40-554 Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ............................................. 40-555 Failure code [DB92KK] Solenoid Power Source Low (BBC) ................................................. 40-557 Failure code [DB95KX] Failure of 5 V Power Source 1......................................................... 40-559 Failure code [DB96KX] Failure of 5 V Power Source 2......................................................... 40-561 Failure code [DB99KQ] Inconsistency of Model Selection (BBC) .......................................... 40-563 Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)................................................ 40-564 Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ................................................ 40-566 Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .................................................. 40-568 Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .................................................. 40-569 Failure code [DB9RMA] Inconsistency of Option Selection (BBC)......................................... 40-570 Failure code [DBE5KX] Failure of 5V Power Source............................................................ 40-571 Failure code [DBE6KX] Failure of 24 V Power Source ......................................................... 40-573 Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................... 40-575 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-577 Failure code [DDB6L4] Neutral Signal Malfunction .............................................................. 40-579 Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ........................................... 40-582 Failure code [DDK3KA] FNR SW Input Signal Disconnection............................................... 40-584 Failure code [DDK3KB] FNR SW Input Signal Short Circuit.................................................. 40-587 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ............................................ 40-589 Failure code [DDK6KB] FNR Lever Input Signal Short Circuit............................................... 40-592 Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................... 40-594 Failure code [DDT0L4] Failure of Shift Mode Select SW ...................................................... 40-596 Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal...................................... 40-598 Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ........................................... 40-600 Failure code [DDW9LD] Ground Fault of Kickdown Switch................................................... 40-602 Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ................................................ 40-604 Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-606 Failure code [DF10KB] Ground Fault of Shift Lever Input ..................................................... 40-608 Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor........................................... 40-611 WA470-7
00-9
00 Index and foreword Index
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ............................................ 40-613 Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor .......................................... 40-615 Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ......................................... 40-617 Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .................................................. 40-618 Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ........................................... 40-620 Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor............................................. 40-623 Failure code [DH21KA] Failure of Loader Pump Press. Sensor ............................................ 40-625 Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit........................................ 40-627 Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ............................................... 40-629 Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor.................................. 40-631 Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor .................................... 40-633 Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor...................................... 40-635 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................... 40-637 Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor .................................. 40-639 Failure code [DHT8KA] Failure of Steering Pump Press. Sensor .......................................... 40-641 Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit...................................... 40-643 Failure code [DHT8ZG] Steering Oil Pressure Low.............................................................. 40-645 Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ......................................... 40-646 Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ............................................ 40-648 Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................................................. 40-650 Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................... 40-652 Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ........................................... 40-655 Failure code [DK55L5] Failure of FNR Lever Potentio.......................................................... 40-657 Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ............................................. 40-658 Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ......................................... 40-661 Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................... 40-664 Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub).............................................. 40-668 Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) .......................................... 40-671 Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ........................................... 40-674 Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ....................................... 40-677 Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................... 40-680 Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ............................................ 40-684 Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ........................................ 40-687 Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ................................................ 40-690 Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ............................................ 40-693 Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree........................................ 40-695 Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub).................................................. 40-698 Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub).............................................. 40-701 Failure code [DKA0KA] Failure of Boom Angle Sensor ........................................................ 40-703 Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .......................................... 40-705 Failure code [DKA0L0] Boom Angle Sensor Dislocation ...................................................... 40-707 Failure code [DKA1KA] Failure of Bucket Angle Sensor....................................................... 40-709 Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit......................................... 40-711 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor........................................ 40-713 Failure code [DLF1LC] Failure of T/M Input Speed Sensor................................................... 40-715 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor.................................. 40-717 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor............................................. 40-719 Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main).................................... 40-721 Failure code [DLT3LC] Failure of Output Speed Sensor (Main)............................................. 40-723 Failure code [DPQ1KR] LIN Discon (Switch Panel) ............................................................. 40-725 Failure code [DPQ2KR] LIN Discon (LED Unit) ................................................................... 40-728 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ..................................................... 40-731 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) .............................................................. 40-734 Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .............................................. 40-736 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. .......................................... 40-738 Failure code [DV00KB] Ground Fault of Buzzer Output........................................................ 40-740 Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................ 40-742 Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise).................................. 40-744 Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................... 40-746
00-10
WA470-7
00 Index and foreword Index
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ............................... 40-748 Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ................................. 40-750 Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ...................................... 40-752 Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) .......................................... 40-754 Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .................................... 40-756 Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt).......................................... 40-758 Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ..................................... 40-760 Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................ 40-762 Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ..................................... 40-764 Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ......................................... 40-766 Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .......................................... 40-768 Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol................................................. 40-770 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ......................................... 40-771 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid........................................... 40-773 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ................................................ 40-775 Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................... 40-777 Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ........................................ 40-779 Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ............................................. 40-781 Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..................................... 40-783 Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)....................................... 40-785 Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ............................................ 40-787 Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol....................................... 40-789 Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................... 40-791 Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................... 40-793 Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ................................. 40-795 Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ................................... 40-797 Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ........................................ 40-799 Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...................................... 40-801 Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ................................ 40-803 Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid...................................... 40-805 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ..................................... 40-806 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................... 40-808 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ............................................ 40-810 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)............................................ 40-812 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ............................................. 40-814 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)................................................... 40-816 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)........................................... 40-818 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ............................................ 40-820 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).................................................. 40-822 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ........................................... 40-824 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ............................................. 40-826 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) .................................................. 40-828 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................... 40-830 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ..................................... 40-832 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)........................................... 40-834 Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) .................................... 40-836 Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward)...................................... 40-838 Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ........................................... 40-840 Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ........................................... 40-842 Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)............................................. 40-844 Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) .................................................. 40-846 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ....................................... 40-848 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)......................................... 40-850 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .............................................. 40-852 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................... 40-854 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ........................................ 40-856 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ............................................. 40-858 Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor........................................... 40-860 Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .......................................... 40-863 WA470-7
00-11
00 Index and foreword Index
Failure code [DY30ME] Emerg. Steering Long-Time Activated ............................................. 40-867 Failure code [LA00L3] Failure of Fan Reverse .................................................................... 40-869 Troubleshooting of electrical system (E-mode) .......................................................................... 40-870 E-1 Engine does not start.................................................................................................. 40-870 E-2 Manual preheating system does not work..................................................................... 40-876 E-3 Automatic preheating system does not work................................................................. 40-879 E-4 While preheating is working, preheating monitor does not light up .................................. 40-881 E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .................. 40-883 E-6 LCD unit on machine monitor displays nothing.............................................................. 40-886 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) .............................................................................................................. 40-888 E-8 LCD on machine monitor does not display properly ....................................................... 40-890 E-9 Meter unit display on machine monitor is abnormal ....................................................... 40-892 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................................. 40-895 E-11 Caution LED on machine monitor is abnormal............................................................. 40-898 E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ............................................................................................................. 40-900 E-13 Two switches operation of switch panel on machine monitor does not function .............. 40-902 E-14 Switch panel buzzer of machine monitor is abnormal................................................... 40-905 E-15 Rear view monitor does not light up or backlight flickers............................................... 40-907 E-16 Rear view monitor images are not displayed clearly..................................................... 40-910 E-17 Rear view monitor brightness cannot be adjusted........................................................ 40-913 E-18 Night lighting lamp of rear view monitor is abnormal .................................................... 40-916 E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ............................................................................................................. 40-918 E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position .............................................................................................................. 40-919 E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ................................................................................................................... 40-923 E-22 Air cleaner clogging indicator lamp does not light ........................................................ 40-925 E-23 Radiator coolant level caution lamp does not light ....................................................... 40-926 E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light................................................................ 40-928 E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ............................................. 40-930 E-26 Fuel level gauge does not indicate correct level .......................................................... 40-931 E-27 Seat belt caution lamp indication is abnormal.............................................................. 40-933 E-28 Horn does not sound ................................................................................................ 40-934 E-29 Horn does not stop sounding..................................................................................... 40-937 E-30 Alarm buzzer does not sound .................................................................................... 40-939 E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................ 40-940 E-32 Kickdown does not work when kickdown switch is turned ON....................................... 40-941 E-33 The hold switch does not work when it is pressed........................................................ 40-943 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..................................................................... 40-945 E-35 Transmission cut-off mode is not selected or not released............................................ 40-948 E-36 Transmission cut-off setting cannot be released .......................................................... 40-950 E-37 Directional selector (FNR) switch mode is not selected or not released ......................... 40-952 E-38 When operating engine power selection switch, engine power selection function does not operate properly ................................................................................................. 40-954 E-39 Flow of loader pump does not increase from the minimum rate..................................... 40-956 E-40 ECSS function cannot be selected or cannot be released ............................................ 40-957 E-41 None of headlamp, clearance lamp, and tail lamp lights ............................................... 40-959 E-42 Clearance lamp and tail lamp do not light up or go out ................................................. 40-961 E-43 Both High and Low beams of headlamp do not light up or go out .................................. 40-964 E-44 Low beam of headlamp does not light up or go out ...................................................... 40-968 E-45 High beam of headlamp does not light up or go out ..................................................... 40-970 E-46 Front working lamp does not light up or go out ............................................................ 40-972 E-47 Rear working lamp does not light up or go out............................................................. 40-975
00-12
WA470-7
00 Index and foreword Index
E-48 All of turn signal lamps and hazard lamps do not light up or go out................................ 40-978 E-49 Turn signal lamps do not light up or go out .................................................................. 40-981 E-50 Hazard lamp does not light up or go out...................................................................... 40-984 E-51 Brake lamp does not light or stays lighted ................................................................... 40-987 E-52 Backup lamp does not light up or does not go out........................................................ 40-990 E-53 Backup buzzer does not sound or continues to sound ................................................. 40-993 E-54 Front wiper does not operate ..................................................................................... 40-995 E-55 Rear wiper does not operate ..................................................................................... 40-998 E-56 Window washer does not operate ............................................................................ 40-1000 E-57 Fuel feed pump does not operate or stop automatically ............................................. 40-1003 E-58 KOMTRAX system does not operate properly........................................................... 40-1005 Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 40-1007 Information described in troubleshooting table (H-mode) ................................................... 40-1007 System chart of hydraulic and mechanical systems........................................................... 40-1008 Failure mode and cause table ..........................................................................................40-1011 H-1 Machine does not move off ....................................................................................... 40-1019 H-2 Torque converter lockup clutch is not disengaged (engine stalls).................................. 40-1022 H-3 Torque converter lockup clutch is not engaged ........................................................... 40-1023 H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift ................................................................................................................. 40-1024 H-5 Large shock is made when machine starts or gear is shifted ........................................ 40-1027 H-6 Machine starts or gear speed shifts with long time lag ................................................. 40-1029 H-7 Torque converter oil temperature is high..................................................................... 40-1031 H-8 Machine does not turn .............................................................................................. 40-1033 H-9 Turning response is poor .......................................................................................... 40-1035 H-10 Steering wheel is heavy to turn................................................................................ 40-1037 H-11 Machine sways or large shocks are made while machine turns .................................. 40-1038 H-12 Turning radius differs between right and left turns...................................................... 40-1040 H-13 Wheel brakes do not work or are weak..................................................................... 40-1041 H-14 Wheel brakes are not released or drag..................................................................... 40-1043 H-15 Parking brake does not work or it is weak ................................................................. 40-1044 H-16 Parking brake is not released or drags (including emergency release system) ............. 40-1045 H-17 Boom does not rise ................................................................................................ 40-1046 H-18 Boom moves slow or boom lacks lifting force ............................................................ 40-1048 H-19 Rising boom slows down at certain height ................................................................ 40-1050 H-20 Lift cylinders do not serve to hold bucket on ground .................................................. 40-1051 H-21 Hydraulic drift of boom is large ................................................................................ 40-1052 H-22 Boom moves up and down during operation ............................................................. 40-1053 H-23 Bucket does not tilt back ......................................................................................... 40-1054 H-24 Bucket moves slow or lacks tilt-back force................................................................ 40-1056 H-25 Bucket decelerates during tilt-back operation............................................................ 40-1058 H-26 Bucket cylinder does not hold bucket on ground ....................................................... 40-1059 H-27 Hydraulic drift of bucket is large ............................................................................... 40-1060 H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ............................................................................................................. 40-1061 H-29 Boom and bucket control levers do not move smoothly and are heavy to move ........... 40-1062 H-30 Operating work equipment causes engine speed to lower significantly or engine to stall ................................................................................................................. 40-1063 H-31 Large shocks are made when work equipment starts to move and stops ..................... 40-1064 H-32 When certain work equipment stalls hydraulically, other work equipment moves ............................................................................................................. 40-1066 H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces................. 40-1067 H-34 Bucket does not stop at the position which is set with remote bucket positioner ........... 40-1068 H-35 Fan speed is abnormal (too high or low, or fan does not rotate) .................................. 40-1069 H-36 Unusual noise is heard from around fan ................................................................... 40-1070 Troubleshooting of engine (S-mode)....................................................................................... 40-1071 Information mentioned in troubleshooting table (S mode)................................................... 40-1071 S-1 When starting switch is turned to START position, engine is not cranked....................... 40-1072 S-2 The engine cranks but exhaust smoke does not come out ........................................... 40-1073 WA470-7
00-13
00 Index and foreword Index
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ........................................................................................................................................................... 40-1074 S-4 Engine startability is poor ...................................................................................................................... 40-1075 S-5 Engine does not pick-up smoothly ...................................................................................................... 40-1077 S-6 Engine stops during operation ............................................................................................................. 40-1079 S-7 Engine runs rough or is unstable ......................................................................................................... 40-1081 S-8 Engine lacks power ................................................................................................................................. 40-1082 S-9 KDPF gets clogged in a short time ....................................................................................................... 40-1084 S-10 Engine oil consumption is excessive ................................................................................................. 40-1086 S-11 Engine oil becomes contaminated early............................................................................................ 40-1087 S-12 Fuel consumption is excessive ............................................................................................................ 40-1088 S-13 Oil is in coolant (or coolant spurts or coolant level goes down)................................................... 40-1089 S-14 Oil pressure drops ................................................................................................................................. 40-1090 S-15 Fuel mixes into engine oil.................................................................................................................... 40-1091 S-16 Water mixes into engine oil (milky) .................................................................................................... 40-1092 S-17 Coolant temperature rises too high (overheating) .......................................................................... 40-1093 S-18 Unusual noise is heard ........................................................................................................................ 40-1094 S-19 Vibration is excessive ............................................................................................................................ 40-1095 S-20 Air cannot be bled from fuel circuit .................................................................................................. 40-1096 S-21 Active regeneration is executed frequently ..................................................................................... 40-1097 S-22 Active regeneration takes a long time............................................................................................... 40-1098 S-23 White smoke is exhausted during active regeneration .................................................................. 40-1099 Troubleshooting of Central Lubrication System (CLS)......................................................................................... 40-1101
50 Disassembly and assembly .............................................................................................................................................. 50-1 Table of contents ............................................................................................................................................................ 50-2 General 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 .................................................................................................................................... 50-17 Engine and cooling system ........................................................................................................................................ 50-47 Removal and installation of supply pump assembly..................................................................................... 50-47 Removal and installation ofi njector assembly............................................................................................... 50-53 Removal and installation off uel doser assembly ........................................................................................... 50-61 Removal and installation of cylinder head assembly..................................................................................... 50-63 Removal and installation of engine hood assembly ..................................................................................... 50-77 Removal and installation of grille assembly ................................................................................................... 50-79 Removal and installation of cooling system assembly.................................................................................. 50-82 Removal and installation of radiator core assembly ...................................................................................... 50-85 Removal and installation of aftercooler............................................................................................................ 50-87 Removal and installation of hydraulic oil cooler ............................................................................................ 50-90 Removal and installation of power train oil cooler assembly ...................................................................... 50-92 Removal and installation of engine assembly ................................................................................................ 50-96 Removal and installation of engine front oil seal ......................................................................................... 50-102 Removal and installation of engine rear oil seal........................................................................................... 50-105 Removal and installation of cooling fan and cooling fan motor assembly ............................................. 50-110 Removal and installation of KDPF assembly................................................................................................. 50-112 Disassembly and assembly of KDPF assembly ............................................................................................. 50-117 Removal and installation of KCCV assembly ................................................................................................ 50-126 Removal and installation of KVGT assembly................................................................................................ 50-128 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly....................................... 50-133 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly..................................... 50-134 Removal and installation of air cleaner assembly ...................................................................................... 50-136 Removal and installation of air conditioner compressor belt .................................................................. 50-138 Removal and installation of alternator belt ................................................................................................. 50-139 Removal and installation off uel tank assembly .......................................................................................... 50-140 Power train................................................................................................................................................................. 50-143 Removal and installation of torque converter and transmission assembly............................................ 50-143 Disassembly and assembly of transmission assembly................................................................................ 50-148 Disassembly and assembly of torque converter assembly ........................................................................ 50-178
00-14
WA470-7