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WHEEL LOADER
WA470-7
Model Serial Number
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
WA470-7 00-3
00 Index and foreword
Index
00-4 WA470-7
00 Index and foreword
Index
WA470-7 00-5
00 Index and foreword
Index
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
00-8 WA470-7
00 Index and foreword
Index
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
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
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 of injector assembly....................................................................... 50-53
Removal and installation of fuel 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 of fuel 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
00 Index and foreword
Index
WA470-7 00-15
00 Index and foreword
Index
00-16 WA470-7
00 Index and foreword
Index
WA470-7 00-17
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Foreword, safety and general information
(Rev. 2012/01)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
00-18 WA470-7
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Foreword, safety and general information
steps when getting on or off the machine. Never • When removing piping, prevent the fuel or oil
jump on or off the machine. When the scaffold is from spilling out. If any fuel or oil drips onto the
not provided, use steps or stepladder to secure floor, wipe it off immediately. Fuel or oil on the
your footing. floor can cause you to slip and can even cause
fires.
Precautions during work • As a general rule, do not use gasoline to wash
• For the machine equipped with the battery parts. Do not use gasoline to clean the electrical
disconnect switch, check that the system parts, in particular.
operating lamp is turned off before starting the • Reinstall the parts removed to their original
work. Then, turn the battery disconnect switch to places. Replace the damaged parts and the
the OFF (Q) position and remove the switch key. parts which must not be used with new ones.
For the machine not equipped with the battery When installing the hoses and wiring harnesses,
disconnect switch, remove the cable from the be careful that they are not damaged by
battery before starting the work. Be sure to contacting with other parts when the machine is
remove the negative end (-) of the battery cable operated.
first. • When connecting the high pressure hoses and
• Release the remaining pressure in the circuits tubes, make sure that they are not twisted. The
completely before the work when the parts in the damaged high pressure hoses and tubes are
circuits of oil, fuel, coolant and air are very dangerous when they are installed. So, be
disconnected or removed. When the cap of the extremely careful when connecting the high
oil filter, drain plug or oil pressure pickup plug is pressure pipings. In addition, check that their
removed, loose them slowly to prevent the oil connections are correct.
from spurting out. • When assembling or installing the parts, be sure
• When removing or installing the checking plug or to tighten the bolts to the specified torque. When
the piping in the fuel circuit, wait 30 seconds or installing the protective parts such as guards, or
longer after the engine is shut down and start the parts which vibrate violently or rotate at high
the work after the remaining pressure is speeds, be sure to check that they are installed
released from the fuel circuit. correctly.
• Immediately after the engine is shut down, the • When aligning two holes, never insert your
coolant and oil in the circuits are hot. Be careful fingers or hand into the holes. Align the holes
not to get scalded by the hot coolant and oil. with care so that your fingers are not caught in
Start the work after checking that the coolant the hole.
and oil are cooled down sufficiently. • When measuring hydraulic pressure, check that
• Start the work after the engine is shut down. Be the measuring tools are correctly installed.
sure to shut down the engine when working on • Pay attention to safety when removing and
or around the rotating parts in particular. When installing the tracks of the track type machines.
checking the machine without shutting down the When removing the track, it separates suddenly.
engine (measuring oil pressure, engine speed, The workers should not stand at either end of
oil or coolant temperature), take extreme care the track.
not to get caught in the rotating parts or the • If the engine is operated for a long time in a
working equipment. closed place which is not ventilated well, you
• The hoist or crane must be used to sling the may suffer from gas poisoning. Accordingly,
components weighing 25 kg or heavier. Check open the windows and doors to ventilate the
the slings (wire rope, nylon sling, chain and place well.
hook) for damage before the work. Use the
slings with ample capacity and install them to Precautions for slinging work and making
the proper places. Operate the hoist or crane signals
slowly to prevent the component from hitting any • Only one appointed worker must make signals
other part. Do not work with any part still raised and co-worker must communicate with each
by the hoist or crane. other frequently. The appointed signaler must
• When removing the part which is under internal make specified signals clearly at the place
pressure or reaction force of the spring, always where the signaler is well seen from the
leave two bolts in diagonal positions. Loosen operator's seat and where the signaler can see
those two bolts gradually and alternately and the working condition easily. The signaler must
release the pressure, then, remove the part. always stand in front of the load and guide the
• When removing the part, be careful not to break operator safely.
or damage the electrical wiring. The damaged 1. Do not stand under the load.
wiring may cause electrical fires. 2. Do not step on the load.
• Check the slings before starting sling work.
WA470-7 00-19
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Foreword, safety and general information
• Keep putting on the gloves during sling work. • Use the specified eye bolts and fix wire ropes,
(Put on the leather gloves, if available.) chains, etc. to them with shackles, etc.
• Measure the weight of the load by the eye and • Apply wire ropes to the middle portion of the
check its center of gravity. hook.
• Use the proper sling according to the weight of
a Slinging near the tip of the hook may cause
the load and method of slinging. If too thick wire
the rope to slip off the hook during hoisting.
ropes are used to sling a light load, the load may
The hook has the maximum strength at the
slip and fall.
middle part.
• Do not sling a load with one wire rope only. If do
so, the load may rotate or the sling gets loose
and the sling may slip off. Install two or more
wire ropes symmetrically.
00-20 WA470-7
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Foreword, safety and general information
WA470-7 00-21
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Foreword, safety and general information
00-22 WA470-7
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WA470-7 00-23
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Foreword, safety and general information
00-24 WA470-7
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Foreword, safety and general information
(Rev. 2012/01)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
described.
Tightening The tightening torques that require special attention during assembly
3 torque work are described.
WA470-7 00-25
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Foreword, safety and general information
6 Drain The places from which oil is drained and quantity of the oil are indicated.
Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
00-26 WA470-7
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Foreword, safety and general information
(Rev. 2012/01)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.
WA470-7 00-27
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Foreword, safety and general information
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.
00-28 WA470-7
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Foreword, safety and general information
(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.
WA470-7 00-29
00 Index and foreword
Foreword, safety and general information
(Rev.2012/01)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.
00-30 WA470-7
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Foreword, safety and general information
(Rev. 2012/01)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never leave the openings of the
pipes and hoses without being covered or Replacing hydraulic oil while its temperature is
high
plugged with cloth as foreign material may enter
• When the hydraulic oil is warm, it flows easily. In
them or environment may be polluted by the oil
addition, sludge can also be drained from the
leaked. Do not discard the waste oil somewhere
circuit together with the oil. So, it is better to
or other. Hand it over to your customer for
change the hydraulic oil while it is warm. When
disposal, or dispose it by yourself.
changing the hydraulic oil, the old oil must be
drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.
WA470-7 00-31
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Foreword, safety and general information
Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.
00-32 WA470-7
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Foreword, safety and general information
k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 (ALL-C930-925-P-01-A)
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the
(Fig. 3) rubber cap will move toward the hose,
however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.
WA470-7 00-33
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Type 2 (ALL-C930-925-P-02-A)
Disconnection Connection
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)
00-34 WA470-7
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Foreword, safety and general information
Type 3 (ALL-C930-925-P-03-A)
Disconnection Connection
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)
WA470-7 00-35
00 Index and foreword
Foreword, safety and general information
(Rev. 2012/01)
• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
00-36 WA470-7
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Foreword, safety and general information
WA470-7 00-37
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Foreword, safety and general information
Connecting connectors
1. Check the connector visually.
00-38 WA470-7
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Foreword, safety and general information
• If the connector clamp is removed, be sure to • If there is any oil or dirt on the wiring harness,
return it to its original position. And check wipe it off with a dry cloth. Avoid washing by
that it is securely installed. using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
WA470-7 00-39
00 Index and foreword
Foreword, safety and general information
Connection
1. Insert the connector securely until a click is
heard. Connection
1. Insert the connector securely until a click is
Slide, lock type (Type 2) (FRAMATOME-24) heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type (PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.
00-40 WA470-7
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Foreword, safety and general information
Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
Push lock type (1) (BOSCH-3) Push lock type (2) (SUMITOMO-4)
Disconnection Disconnection
1. While pressing lock (C), pull out connector (3) in 1. While pressing lock (C), pull out connector (4) in
the direction of the arrow. the direction of the arrow.
• 114 series Connection
1. Insert the connector securely until a click is
heard.
• 107 series
WA470-7 00-41
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Foreword, safety and general information
Connection
1. Insert the connector to the end while aligning its
Example) Speed sensor of supply pump: G grove to the other.
(SUMITOMO-3) 2. Turn housing (H1) in the direction of the arrow
until it "clicks".
a Pull the connector straight up.
00-42 WA470-7
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Foreword, safety and general information
WA470-7 00-43
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Foreword, safety and general information
00-44 WA470-7
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Foreword, safety and general information
Dimension
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 —
Coating D
AV Standard — — — — — — — 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
WA470-7 00-45
00 Index and foreword
Foreword, safety and general information
a Remarks: In a color code consisting of two colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
00-46 WA470-7
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Foreword, safety and general information
(Rev. 2012/01)
• When performing "removal or installation" and "disassembly or assembly" of the components, observe the
following general cautions.
WA470-7 00-47
00 Index and foreword
Foreword, safety and general information
If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal No. Part No.
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
00-48 WA470-7
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a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
WA470-7 00-49
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00-50 WA470-7
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WA470-7 00-51
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Foreword, safety and general information
(Rev. 2012/01)
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2. The following table applies to the bolts in Fig. B.
Thread Width Tightening torque
diameter across flats
(mm) (mm) (Nm) (kgm)
6 10 5.9 to 9.8 0.6 to 1.0
8 12 13.7 to 23.5 1.4 to 2.4
10 14 34.3 to 46.1 3.5 to 4.7
12 17 74.5 to 90.2 7.6 to 9.2
Fig. A Fig. B
a Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)
00-52 WA470-7
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WA470-7 00-53
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Foreword, safety and general information
Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a The table is applied to the threads coated with engine oil (wet threads)
Tightening torque (Nm {kgm}) Taper seal Face seal
Width
Nominal across Nominal No. - Thread root
No. of Thread size threads per
flats Range Target diameter
hose (mm) (mm) inch, type of (reference)
thread
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16 -18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16 -16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/16 -16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1-3/16 -12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —
00-54 WA470-7
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Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Thread diameter Tightening torque
(mm) (Nm) (kgm)
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
Tightening torque table for I-joints on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to the
torque shown in the following table.
Thread diameter Tightening torque
(mm) (Nm) (kgm)
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
Tightening torque table for tapered screws on 102,107 and 114 series engines
a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Material In cast iron or steel In aluminum
Tightening torque Tightening torque
Thread diameter (inch)
(Nm) (kgm) (Nm) (kgm)
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
WA470-7 00-55
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00-56 WA470-7
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WA470-7 00-57
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00-58 WA470-7
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WA470-7 00-59
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00-60 WA470-7
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WA470-7 00-61
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Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilograms to pounds
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
l to U.S. Gallons
1 l= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
00-62 WA470-7
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l to U.K. Gallons
1 l= 0.21997 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
WA470-7 00-63
00 Index and foreword
Foreword, safety and general information
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
00-64 WA470-7
00 Index and foreword
Foreword, safety and general information
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
WA470-7 00-65
00 Index and foreword
Foreword, safety and general information
00-66 WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model Serial Number
01 Specification
2 01 Specification
WA470-7 01-1
01 Specification
Table of contents
01-2 WA470-7
01 Specification
Specification drawing
Specifications (ALL-2111-001-A-00-A)
WA470-7
Item Unit
(in P mode)
Machine weight (with BOC) kg 23,510
Operating load kg 6,720
Bucket capacity (heaped, with BOC) m3 4.2
Engine model - Komatsu SAA6D125E-6 diesel engine
Rated horsepower
• SAE J1995 [Gross] (*1) kW {HP} / 204 {273}/ 2,000 {2,000}
• ISO 14396 min-1 {rpm} 204 {273}/ 2,000 {2,000}
• ISO 9249/ SAE J1349 [Net] (*2) 203 {272}/ 2,000 {2,000}
A Overall length (with BOC, additional weight) mm 8,825
B Overall height mm 3,500
C Overall height with bucket at max. height mm 5,960
D Overall width mm 3,010
E Min. ground clearance mm 525
F Bucket width mm 3,170
G Dumping clearance (*3) Bucket tip / BOC tip mm 3,270/3,185
H Dumping reach (*3) Bucket tip / BOC tip mm 1,190/1,235
I Dumping angle deg. 45
Bucket tip / BOC tip mm 7,615/7,650
Min. turning radius
Center of outside tire mm 6,630
Allowable towing load kN {kg} 171 {17,400}
1st (forward/reverse) 7.6/7.9
locked up travel speed 2nd (forward/reverse) 13.2/13.7
(P mode) km/h
3rd (forward/reverse) 23.6/24.3
4th (forward/reverse) 38.3/39.0
*1: Indicates the value of the basic engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
*3: Indicates the value when the tilt down angle of bucket is 45 degrees.
WA470-7 01-3
01 Specification
Specification drawing
a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.
a Following shows the rated horsepower (net) at the maximum cooling fan speed.
194 kW {260 HP}/ 2,000 min-1 {2,000 rpm}
a BOC: Abbreviation for Bolt On Cutting edge
01-4 WA470-7
01 Specification
Specifications
Specifications (WA470_7-2111-931-A-00-A)
km/h
Reverse 4th 31.7 37.3
Travel speed
km/h
Forward 3rd 20.4 23.6
Forward 4th 33.1 38.3
Reverse 1st 6.8 7.9
Reverse 2nd 11.8 13.7
Reverse 3rd 21.1 24.3
Reverse 4th
km/h
34.2 39.0
WA470-7 01-5
01 Specification
Specifications
01-6 WA470-7
01 Specification
Specifications
Dimension
Machine model WA470-7
Serial No. 10001 and up
Overall length (with BOC) mm 8,825
Overall width (machine body) mm 3,010
Bucket width (with BOC) mm 3,170
Overall height (top of cab) mm 3,500
Overall height with bucket at max.
mm 5,960
height
Wheelbase mm 3,450
Tread mm 2,300
Min. ground clearance mm 525
Max. hinge pin height mm 4,360
Dumping clearance (*1)
mm 3,270/3,185
(cutting edge tip/BOC tip)
Dumping reach (*1)
mm 1,190/1,235
(cutting edge tip/BOC tip)
Steering angle deg. 35
Tilt back angle of bucket (travel posture/
deg. 50/65
max. height)
Tilt down angle of bucket (max. height) deg. 45
Digging depth, 10 deg. (cutting edge tip/
mm 265/315
BOC end)
*1: Indicates the value when the tilt down angle of bucket is 45 degrees.
a BOC: Abbreviation for Bolt On Cutting edge
WA470-7 01-7
01 Specification
Specifications
Engine
Machine model WA470-7
Serial No. 10001 and up
Model SAA6D125E-6
4-cycle, water-cooled, in-line vertical, direct injection,
Type with turbocharger, air-cooled aftercooler, and water-
cooled EGR
No. of cylinders – bore x stroke mm 6 - 125 x 150
Total piston displacement l {cc} 11.04 {11,040}
Rated horsepower
Performance (In P mode)
01-8 WA470-7
01 Specification
Specifications
Tire
Machine model WA470-7
Serial No. 10001 and up
Size 26.5R25 AA L - 3
Rim size 22.00 - 25WTB
Inflation pressure
• Front wheel kPa 450 {4.5}
• Rear wheel {kg/cm2} 350 {3.5}
Brake
Machine model WA470-7
Serial No. 10001 and up
4-wheel braking, braking with independent front and
Braking method
rear wheel systems
Main
• Discharge cm3/rev 90
Work equipment pump
• Type Variable displacement swash plate piston type
• Discharge cm3/rev 120
Cooling fan pump
• Type Variable displacement swash plate piston type
• Discharge cm3/rev 30
Emergency steering pump
• Type Gear type
• Discharge cm3/rev 21
WA470-7 01-9
01 Specification
Specifications
Hydraulic system
Machine model WA470-7
Serial No. 10001 and up
Type Double-acting piston type
Steering cylinder
Cylinder bore mm 90
Piston rod outside diameter mm 50
Stroke mm 441
Max. distance between pins mm 1,296
Min. distance between pins mm 855
Type Double-acting piston type
Lift cylinder
MPa {kg/
• Set pressure 34.3 {350}
cm2}
Steering valve
• Type Spool type
MPa {kg/
• Set pressure 24.5 {250}
cm2}
Cooling fan motor
Motor
01-10 WA470-7
01 Specification
Weight table
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model WA470-7
Serial No. 10001 and up
Engine (excluding coolant and oil) 1,486
Cooling assembly (including fan, frame, and air conditioner condenser)
(excluding coolant and oil) 369
• Cooling sub assembly (excluding fan, cooling fan motor, frame, coolant,
and oil) 204
• Radiator (1 piece) 33
• Aftercooler 25
• Oil cooler 7
• Air conditioner condenser 3
• Cooling fan motor 14
Torque converter oil cooler 25
Cooling fan pump 25
Transmission (including torque converter)
Without lockup clutch 1,148
With lockup clutch 1,193
Front drive shaft 33
Center drive shaft 40
Rear drive shaft 20
Front axle
With conventional differential 1,238
With limited slip differential 1,250
Rear axle
with conventional differential 1,168
With limited slip differential 1,180
Axle pivot (rear axle) 144
Tire and rim assembly (26.5 - R25 AA L - 3) (1 piece) 655
• Tire (26.5R25 AA L - 3) (1 piece) 415
• Rim (22.00-25WTB) (1 piece) 240
Power train pump 20
Work equipment pump 103
Steering pump 40
Work equipment control valve 108
Work equipment EPC valve 4
Brake valve 7
Steering valve 24
Emergency steering motor 13
Emergency steering pump 3
Steering cylinder assembly (1 piece) 37
Lift cylinder assembly (1 piece) 185
Bucket cylinder assembly 206
Front frame 1,852
Rear frame 1,735
Counterweight 1,595
Additional weight 385
WA470-7 01-11
01 Specification
Weight table
Unit: kg
Machine model WA470-7
Serial No. 10001 and up
Engine hood assembly (including hydraulic tank, hydraulic tank mounting
bracket, hood, grille assembly, and upper portion of bulkhead) 690
• Food body (excluding hydraulic tank hydraulic tank mounting bracket) 428
• Hood 38
• Side door (1 piece) 47
• Grille 87
• Mask 25
• Hydraulic tank (excluding hydraulic oil) 168
• Hydraulic tank mounting bracket 68
Fuel tank (excluding fuel) 194
Boom (including bushings) 1,470
Bucket link 89
Bell crank 390
Bucket (3,170 mm wide, including BOC side guard) 2,023
Operator's cab (including floor assembly) 1,078
Operator's seat 50
Air conditioner unit 5
Battery (1 piece) 45
01-12 WA470-7
01 Specification
Table of fuel, coolant, and lubricants
a For details of notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
WA470-7 01-13
01 Specification
Table of fuel, coolant, and lubricants
Unit: l
Refill point Specified capacity Refill capacity
Engine oil pan 47 38
Transmission case 76 65
Hydraulic oil system 270 173
Axle (front / rear) 57/56 57/56
Cooling system 80 ―
Fuel tank 380 ―
01-14 WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model Serial Number
WA470-7 10-1
10 Structure and function
Table of contents
10-2 WA470-7
10 Structure and function
Table of contents
WA470-7 10-3
10 Structure and function
Engine related parts
1. Air cleaner
10-4 WA470-7
10 Structure and function
Engine related parts
2. KDPF (*1)
3. KVGT (*2)
4. Alternator
5. Engine mount
6. EGR cooler (*3)
7. Starting motor
8. Engine oil filter
9. Engine controller
10. KCCV ventilator (*4)
11. Vibration damper
*1: For KDPF, see "KDPF".
*2: For KVGT, see "KVGT".
*3: For the EGR cooler, see "EGR cooler".
*4: For the KCCV ventilator, see "KCCV ventilator".
WA470-7 10-5
10 Structure and function
KVGT
KVGT (ENG125-AA10-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and denotes the variable displacement
turbocharger.
a The shape is subject to machine models.
10-6 WA470-7
10 Structure and function
KVGT
1. Blower housing
2. KVGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10. Blower impeller
11. Turbine impeller
12. Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
Operation (ENG125-AA10-044-K-00-A)
1. Air cleaner
2. KVGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
• The new exhaust gas regulation not only requires to control emissions at high engine speed but also at
low engine speed. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/
intake air flow)
• To obtain a high EGR ratio especially at low engine speed, the turbine inlet pressure (P3) must be higher
than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas
pressure hitting the turbine impeller (T) can be adjusted, is introduced.
• The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to
insufficient oxygen at low engine speed.
• The turbine impeller (T) drives the blower impeller (C) via a shaft to send a large amount of air to the
cylinders for combustion. When the air flow from KVGT (2) increases, more fuel can be injected, and the
engine output increases.
• Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be
injected, and the engine output increases.
WA470-7 10-7
10 Structure and function
KVGT
a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
• Exhaust gas enters from (C) of turbine housing (4), and flows out from (D) through section (P). Section (P)
is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).
• The passage area varies when push rod (8) slides right or left.
• The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled
at the EPC valve installed to the front cover, and also controls the right/left slide of push rod (8).
• Exhaust gas flows through vanes (6) and rotates turbine impeller (11), the torque of which rotates blower
impeller (10) via shaft (9). This works as a compressor and the air entered from (A) is compressed and
sent out from (B).
• When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speed), push
rod (8) slides to the right to narrow section (P).
• Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases,
and more air (oxygen) is inhaled.
• The turbocharger speed is sensed by KVGT speed sensor (2).
10-8 WA470-7
10 Structure and function
KVGT
a Nozzle ring (7), vane (6) and rod (8) are integrated and slide together but do not rotate.
a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated
together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT
position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the
whole KVGT.
Hydraulic actuator operation
• Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to the front cover.
• The force for the movement is the oil pressure supplied from boost pump (12).
a The shape is subject to machine models.
WA470-7 10-9
10 Structure and function
KVGT
• Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to
engine controller (7).
1. Air cleaner
2. Mass air flow and temperature sensor
10-10 WA470-7
10 Structure and function
KVGT
3. KVGT
4. KVGT speed sensor
5. KVGT position sensor
6. Hydraulic actuator
7. Engine controller
8. EPC valve (for KVGT)
9. KDPF
10. EGR system (EGR cooler and EGR valve)
11. EGR valve lift sensor
C. Blower impeller
T. Turbine impeller
Lubrication
• Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication
• Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil
pan.
Cooling
• Coolant from the cylinder block enters the center housing to cool the KVGT.
• Returning coolant flows from the center housing to the radiator.
WA470-7 10-11
10 Structure and function
EGR system piping drawing
1. KVGT
2. EGR valve
3. Air intake connector
4. Intake manifold
5. Exhaust manifold
6. EGR cooler
7. Mixing connector
Function (ENG107-A9J0-042-K-00-A)
10-12 WA470-7
10 Structure and function
EGR system piping drawing
• EGR cooler
Cools the exhaust gas.
Engine coolant is used for cooling.
• Air intake connector
Returns the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side.
• Each sensor
Controls the EGR according to the operating condition.
Troubleshoots the system.
• Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to
ensure clean exhaust at all times.
• Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.
WA470-7 10-13
10 Structure and function
EGR system circuit diagram
1. Air cleaner
2. KDPF
3. Ambient pressure sensor
4. Aftercooler
5. EGR cooler
6. EGR valve
7. Hydraulic actuator (power piston)
8. EPC valve (for EGR valve)
9. EGR valve lift sensor
10. Exhaust manifold
11. Boost pump
12. Intake manifold
13. Charge (boost) pressure and temperature sensors
14. Engine controller
15. Mixing connector
C: Blower impeller
T: Turbine impeller
Operation (ENG125-A9J0-044-K-00-A)
• The engine controller outputs signals for opening EGR valve (6) most properly according to the load on
the engine to attain both clean exhaust gas and low fuel consumption.
• When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10)
through EGR piping to EGR cooler (5).
• The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in
mixing connector (15), and then flows into intake manifold (12).
10-14 WA470-7
10 Structure and function
EGR valve
1. Valve
2. Spring
3. Power piston
4. Spool
5. Spring
6. EGR valve lift sensor
7. EPC valve (for EGR)
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
C: Servo drive oil inlet
D: Servo drive oil outlet
Structure
• The EGR valve consists of the EGR gas flow control mechanism and the EPC valve .
• An EPC valve is provided for EGR valve control, and an EPC valve for KVGT control is installed to front
cover.
WA470-7 10-15
10 Structure and function
EGR valve
Operation (ENG107-A9K1-044-K-00-A)
• Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve
flows into port (E).
• Spool (4) is pressed to the right by the force of spring (5), and EGR valve (1) is closed by the force of
spring (2) Therefore, exhaust gas from the EGR cooler does not flow to the intake side.
• To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a
position whereat this control pressure and the force of spring (5) are balanced.
• The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port
(C) pushes power piston (3) to the left.
• Oil from the boost oil pump acts on power piston (3) and generates force (Fp).
• When force (Fp) becomes larger than force (Fs) of spring (2), EGR valve (1) opens and then exhaust gas
will flow to the intake side.
• Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at
a position determined by spool (4).
• The valve position is controlled by the engine controller by controlling the spool position with the control
pressure of the EPC valve.
• A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in
contact with power piston (3).
• Position of spool (4) is sensed by the EGR valve lift sensor.
10-16 WA470-7
10 Structure and function
EGR cooler
1. Header plate
4. Shell
A: EGR gas inlet
B: EGR gas outlet (to EGR valve)
C: Coolant inlet
D: Coolant outlet
E: Air vent
F: Air vent
2. Flat tube
3. Inner fin
Operation (ENG125-A9L0-044-K-00-A)
• The EGR gas enters from (A) and flows through 9 flat tubes (2).
WA470-7 10-17
10 Structure and function
EGR cooler
• Coolant enters from (C) and flows around flat tube (2) in shell (4) and then goes out from (D).
• The EGR gas is effectively cooled by flat tubes (2) with inner fins (3) and flows out from EGR gas outlet
(B).
10-18 WA470-7
10 Structure and function
KCCV layout drawing
1. KCCV ventilator
2. KVGT
3. Check valve
4. CDR valve
A: Blowby gas
B: Engine oil-free blowby gas (to KVGT)
C: Engineoil that C is separated (to oilpan)
• Formerly blowby gas (A) was discharged to the atmosphere as is. However, the tightened exhaust gas
regulation no longer permits releasing blowby gas to the atmosphere.
• Since blowby gas (A) contains engine oil components, which may cause the following problems when
recirculated to KVGT (2), a filter is provided at KCCV ventilator (1) to remove the oil.
1. Degraded performance of turbocharger and aftercooler due to adherence of engine oil
2. Abnormal engine combustion
3. Malfunction of sensors due to adherence of engine oil
WA470-7 10-19
10 Structure and function
KCCV layout drawing
Operation (ENG125-A180-044-K-00-A)
a The figure on the left shows the traditional flow of blowby gas that has been discharged to the atmosphere.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.
1. Air cleaner
2. KVGT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
• Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the KVGT.
• Separated engine oil (C) flows through a check valve and falls to the oil pan.
10-20 WA470-7
10 Structure and function
KCCV ventilator
1. Case
2. CDR valve
3. Crankcase pressure sensor
4. Relief valve
5. Impactor
6. Filter
7. Heater tube
A: Blowby gas inlet (engine breather)
B: Blowby gas outlet (to KVGT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlets
Function (ENG125-A18H-042-K-00-A)
• When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase
becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve
(regulator valve) controls the pressure inside the crankcase.
• If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog
of filter is detected by crankcase pressure sensor.
• There are two types of filters that differ by the filter replacement method; the top load type (removed
upward) and the bottom load type (removed downward).
• Warmed engine coolant is conducted to the locations that pose potential problem of freezing to prevent it
from happening.
WA470-7 10-21
10 Structure and function
KCCV ventilator
Operation (ENG107-A18H-044-K-00-A)
• Blowby gas enters from (A). The larger drops of oil mist are removed from the blowby gas when it flows
through the impactor (5) holes in filter (6).
• Smaller drops of oil mist are removed by filter (6).
• Removed oil flows down along the case wall to oil drain port (C) and then flows to the oil pan.
• The CDR valve operates when the pressure inside the crankcase becomes negative, to prevent excessive
negative pressure in the crankcase.
• Crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).
• When the engine controller determines that the filter is clogged from crankcase pressure sensor (3)
signals, failure code CA555 is issued. If the pressure increases further, failure code CA556 is issued.
• Relief valve (4) is installed in case (1). It operates to protect the KCCV ventilator and engine when filter (6)
is blocked.
CDR valve (ENG107-A18A-041-K-00-A)
1. Diaphragm
2. Spring
A: Crankcase side
B: KVGT side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
KVGT side (intake side) (B).
• When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases,
force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily
blocks the flow.
• Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.
10-22 WA470-7
10 Structure and function
KDPF
KDPF (ENG125-A9H0-041-K-00-A)
1. Inlet unit
2. KDOC inlet temperature sensor
3. KDOC outlet temperature sensor
4. KCSF unit
5. Aggregate connector box
6. KDPF outlet temperature sensor
7. Outlet unit
8. KDPF differencial pressure sensor port
9. KDPF differencial pressure sensor
10. KDPF differential pressure sensor port
11. KDOC unit
12. Hanger bracket
13. Sensor bracket
14. Sensor bracket band
15. Water drain port
A: From KVGT
B: Exhaust
C: Water drain
• The KDPF consists of the following components: inlet unit (1) to introduce exhaust gas, KDOC unit (11)
that houses an oxidation catalyst, KCSF unit (4) that houses a soot collecting filter with a catalyzer, and
outlet unit (7) that sends out exhaust gas and has a "dam" to prevent rain water from entering KCSF unit
(4).
WA470-7 10-23
10 Structure and function
KDPF
• KDOC unit (11) consists of a ceramic honeycomb coated with oxidation catalyst material. By using this
ceramic honeycomb, it regenerates (*1) NO (nitrogen monoxide) to NO2 (nitrogen dioxide) in exhaust gas.
• The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine
and machine vibrations.
• The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the
ceramic honeycomb during operation.
• The KCSF unit (4) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the
KDOC unit (11). This ceramic honeycomb collects soot.
• Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure
and KDPF outlet pressure sensor) are installed to the KDPF.
• Temperature signals from these three temperature sensors are used in combination to monitor the KDOC
and KCSF operations and to perform various troubleshootings.
• The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the
pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various
troubleshootings.
*1: Denotes to purification (oxidation) processing of soot.
k While engine is running and for some time after engine is stopped, the surface of KDPF and
nearby piping are extremely hot. Be careful not to get burned when working near the KDPF.
Function (ENG125-A9H0-042-K-00-A)
10-24 WA470-7
10 Structure and function
KDPF
• Inside the KCSF (2), there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and
cells plugged at the outlet side are alternately arranged.
• The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1)
(oxidation catalyzer), in operating conditions with relatively high exhaust gas temperatures. (This is
referred to as "passive regeneration".)
• On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low
load operations, the deposit of soot in KCSF (2) increases.
• The engine controller continuously monitors the amount of deposited soot by estimating from the
operating conditions and calculating based on the KCSF (2) differential pressure sensor signals.
• When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas
temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn
(oxidize) the soot.
• During automatic regeneration, the engine controller automatically controls the fuel injection timing and
the KVGT to raise the exhaust temperature. (This operation is called "exhaust temperature-raising
control")
• As the exhaust temperature increases, the engine controller automatically performs calculations based on
the exhaust temperature at the KDOC inlet and flow of the exhaust gas, so that KCSF (2) can efficiently
burn (oxidize) the soot.
• Fuel is injected from (fuel doser) installed to the outlet portion of turbocharger. (Fuel dosing) Fuel that is
injected into this piping mixes with exhaust gas and combusts (oxidizes) soot by the action of KDOC (1).
• Automatic regeneration is not performed when regeneration is executed from the machine monitor, or
when the outside air temperature is extremely low, and when the exhaust gas temperature is not high
enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in
the KCSF (2) will increase.
• If the soot deposit in the KCSF (2) exceeds a certain level, it will be necessary to perform "manual
stationary regeneration" to burn away (oxidize) the soot in the KCSF (2).
• If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase
fuel consumption, degrade engine combustion, or cause other problems.
• If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and
replacement becomes unavoidable. Make sure to follow the procedures in the Operation and
Maintenance Manual when performing "manual stationary regeneration"
Displaying KDPF regeneration (HM400-A9H0-042-K-00-A)
a Regeneration refers to a new function used for purifying (oxidizing) soot accumulated in the soot collection
filter (KCSF) inside the KDPF.
1. Passive regeneration
When the engine exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will
be stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration (increase of engine exhaust temperature + fuel dosing)
1) Automatic regeneration
This is the regeneration process started automatically when the soot deposit exceeds a certain level.
At this time, the engine controller performs the exhaust temperature-raising control mode (*1) and fuel
dosing (*2). Another type of automatic regeneration is performed by the engine controller at certain
intervals, regardless of the amount of soot deposited in the KCSF.
*1: The fuel injection timing and the KVGTare controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process.
2) Manual stationary regeneration
When the exhaust temperature does not reach a certain level due to the machine operating condition,
or when regeneration is disabled by the operator, automatic regeneration will not be performed and the
soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual
stationary regeneration request, on the screen. The operator must perform regeneration by operating
the machine monitor on its screen. A regeneration feature is also provided for the technician who
should use this feature from the machine monitor menu after engine controller replacement, KDPF
replacement, and KCSF ash cleaning. (= Regeneration for service)
• A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF
when the machine is operated for a long time with low exhaust temperature.
WA470-7 10-25
10 Structure and function
KDPF
• When certain conditions are met, the engine controller automatically switches control to increase
the exhaust temperature to dry the KDOC. If some of the conditions for automatic drying are not
met, manual stationary regeneration may be requested.
a Follow the procedures in the Operation and Maintenance Manual when starting and stopping KDPF
regeneration.
a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure.
a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause
KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure.
a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the KDPF,
leading to a failure.
a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a
ceramic honeycomb, which can be damaged by strong impacts.
a The engine controller performs automatic regeneration even when the amount of soot deposit is low.
Since this is programmed to maintain the KDPF performance, this is normal.
a During automatic regeneration and manual stationary regeneration, the KVGTautomatically
operates and the engine sound changes. The flow of exhaust gas through the KDPF changes and
the exhaust sound changes, but this is normal.
a During automatic regeneration and manual stationary regeneration, especially at low temperatures,
white smoke may come out from the exhaust pipe for a short time, but this is normal. Be sure to
perform regeneration at a well ventilated place since carbon monoxide can be produced.
a During automatic regeneration and manual stationary regeneration, a strange odor may be smelled
from the exhaust pipe, but this is normal.
a During automatic regeneration and manual stationary regeneration, the exhaust temperature at the
exhaust pipe can exceed 650°C. Make sure that there is no flammable material near the exhaust
system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe, and pay
sufficient attention to safety of the environment.
a KDPF temperature values are shown below for reference.
KDOC_In KDOC_Out KDPF_Out
(KDOC inlet temperature (KDOC outlet (KDPF outlet
sensor) temperature sensor) temperature sensor)
Not regenerating (idling) 100 to 250°C
Regenerating (under
exhaust temperature-raising 100 to 250°C 400 to 550°C
control: 1,000 rpm)
10-26 WA470-7
10 Structure and function
Cooling system
WA470-7 10-27
10 Structure and function
Cooling system
10-28 WA470-7
10 Structure and function
Cooling system
Specifications (WA470-B000-030-K-00-A)
WA470-7 10-29
10 Structure and function
Cooling fan pump
10-30 WA470-7
10 Structure and function
Cooling fan pump
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball retainer
WA470-7 10-31
10 Structure and function
Cooling fan pump
Structure
• Cylinder block (7) is supported on shaft (1) by spline (a).
• Shaft (1) is supported by each bearing at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) pivot on ball retainer (11).
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while blocking the pressurized oil.
• This plane is designed so that the oil pressure is balanced correctly.
• The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (7)
through valve plate (8).
Specifications (WA470-B450-030-K-00-A)
Model LPV30
Type Variable displacement swash plate type piston pump
Theoretical discharge (cm3/rev) 30
Fan drive pressure (MPa {kg/cm2}) 10.9 {111}
Rated speed (rpm) 2,282
Function (WA380-B450-042-K-00-A)
• The engine rotation and torque transmitted to the pump shaft is converted into the hydraulic energy and
the pressurized oil corresponding to the load is discharged.
• It is possible to change the delivery by changing the swash plate angle.
10-32 WA470-7
10 Structure and function
Cooling fan pump
Operation (WA380-B450-044-K-00-A)
Operation of pump
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) pivots on ball retainer (11), and accordingly angle (a) between center line (X) of rocker
cam (4) and the axial direction of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane
(A) works as a cam for shoe (5).
• Pistons (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
• Oil in amount of (F) minus (E) goes in and out of each cylinder.
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (F) increases.
• In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge
stroke.
WA470-7 10-33
10 Structure and function
Cooling fan pump
• When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (7) is zero.
• Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however,
the swash plate angle does not become 0 deg.)
• The pump delivery is in proportion to swash plate angle (a).
10-34 WA470-7
10 Structure and function
Cooling fan pump
Control of delivery
• When swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
delivery (Q) is increased.
• Swash plate angle (a) is changed by servo piston (10).
• Servo piston (10) reciprocates linearly according to the signal pressure of the servo valve.
• This straight line movement is transmitted to rocker cam (4).
• Rocker cam (4) supported with ball retainer (11) pivots on ball retainer (11).
WA470-7 10-35
10 Structure and function
Cooling fan pump
10-36 WA470-7
10 Structure and function
Cooling fan pump
Function (PC400-B4H0-042-K-00-A)
• The servo valve controls the pump so that the input current (i) to the EPC valve relates to pump delivery
(Q) as shown in the figure below.
Operation (PC400-B4H0-044-K-00-A)
• The output pressure of the EPC valve enters piston chamber (C) and pushes piston (6).
• Piston (6) pushes spool (5) and moves to a position where it is balanced with the spring.
• Land (PE) of the servo piston pressure passage is connected to pump delivery pressure passage (PH)
through the notch of spool (5), so the pump delivery pressure is transmitted to servo piston (10).
• Rocker cam (9) is pushed up by servo piston (10), and then its position is fed back and lever (2) moves to
compress spring (8).
WA470-7 10-37
10 Structure and function
Cooling fan pump
• If spool (5) is pushed back, the pump delivery circuit and servo piston circuit are disconnected.
• The pressure in the servo piston chamber decreases and rocker cam (9) moves toward the maximum
swash plate angle.
• These processes are repeated until the swash plate stabilizes at an angle where the EPC output pressure
is balanced with the force of spring (8).
• As the EPC output pressure increases, the swash plate angle decreases. As the EPC output pressure
decreases, the swash plate angle increases.
10-38 WA470-7
10 Structure and function
Cooling fan motor
WA470-7 10-39
10 Structure and function
Cooling fan motor
1. Output shaft
2. Case
3. Thrust plate
4. Piston assembly
5. Cylinder block
6. Valve plate
7. End cover
8. Center spring
9. Check valve
10. Pilot valve
11. Reversible valve spool
12. Safety valve
13. Cooling fan speed sensor
Specifications (WA470-B5L0-030-K-00-A)
Model LMF28
Capacity (cc/rev) 28.0
Rated speed (rpm) 1,300
Rated flow rate (l/min) 36.4
Check valve cracking pressure (MPa {kg/
0.044 {0.45}
cm2})
10-40 WA470-7
10 Structure and function
Cooling fan motor
• This hydraulic motor is called a swash plate axial piston motor. It converts the energy of the pressurized oil
sent from the hydraulic pump into rotary motion.
• This fan motor is installed within the blade width as shown in the figure.
• The pressurized oil sent from the pump flows through valve plate (3) into cylinder block (5).
• This oil can flow to only one side of the (Y - Y) line connecting the top dead center and bottom dead center
of the stroke of piston (4).
• The pressurized oil sent to one side of cylinder block (5) pushes each piston (4) (two or three pistons).
• A single piston generates force F1 [F1 (kg) = P (kg/cm2) x xD2 / 4 (cm2)].
• This force acts on thrust plate (2).
• Since thrust plate (2) is fixed at specific angle (a) to output shaft (1), the force is divided into components
(F2) and (F3).
• Of those components, radial component (F3) generates torque (T = F3 x ri) against the (Y - Y) line
connecting the top dead center and bottom dead center.
• The total of these torque [T = s (F3 x ri)] rotates cylinder block (5) through piston (4).
• Cylinder block (5) is connected to output shaft (1) with spline.
• Output shaft (1) rotates to transmit the torque.
WA470-7 10-41
10 Structure and function
Cooling fan motor
10-42 WA470-7
10 Structure and function
Cooling fan motor
Operation (WA500-B6D0-044-K-00-A)
• The pressurized oil from the pump is supplied to port (P), increasing the (MA) side pressure.
• The starting torque is generated in the motor, and the motor starts rotating.
• The pressurized oil on the motor outlet (MB) side returns to the tank through port (T).
WA470-7 10-43
10 Structure and function
Cooling fan motor
• When the engine stops, the pump input speed becomes 0 rpm.
• The pressurized oil from the pump is not supplied to port (P).
• As the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to
stop.
• When the motor shaft is rotated by the force of inertia while the oil flow in port (P) is decreasing, the oil in
port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent cavitation.
Reversible valve (WA500-B6E0-041-K-00-A)
The rotating direction of the fan motor changes from the normal rotation to the reverse rotation, or from the
reverse rotation to the normal rotation corresponding to the current data which controls the pilot valve.
• When changing from the normal rotation to the reverse rotation:
The solenoid valve controls the spool position according to the command current which is output from
controller in proportion to the set rate. While the command current passes the neutral range area, the fan
becomes neutral and the fan speed decreases sufficiently. As a result, the direction of the fan changes to
reverse rotation smoothly.
• The fan rotation changes similarly from reverse to normal.
10-44 WA470-7
10 Structure and function
Cooling fan motor
Function (PC400-B6G0-042-K-00-A)
• When the engine is started, the pressure in port (P) of the fan motor is increased in some cases.
• Safety valve (1) is provided in order to protect the fan system circuit.
Operation (WA500-B6G0-044-K-00-A)
• If the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1)
opens to release the pressurized oil into port (T).
• This operation prevents the generation of the abnormally high pressure in port (P).
WA470-7 10-45
10 Structure and function
Power train system
1. Transmission
2. Torque converter
3. Engine
4. Rear axle
5. Rear drive shaft
6. Center drive shaft
7. Front drive shaft
8. Front axle
10-46 WA470-7
10 Structure and function
Power train system
1. Front axle
2. Differential
3. Wet-type multiple-disc brake
WA470-7 10-47
10 Structure and function
Power train system
4. Final drive
5. Front drive shaft
6. Center drive shaft
7. Parking brake (wet-type multiple-disc)
8. Transmission (counter-shaft type)
9. Rear drive shaft
10. Rear tire
11. Final drive
12. Wet-type multiple-disc brake
13. Differential
14. Rear axle
15. Engine
16. Torque converter
17. Steering pump
18. Power train pump
19. Work equipment pump
20. Cooling fan pump
21. Flange bearing
22. Front tire
Function (WA470-C100-042-K-00-A)
• The power of engine (15) is transmitted to torque converter (16) through the flywheel.
The torque converter converts the received torque to the torque corresponding to the fluctuation of the
load by using oil as a medium, and transmits it to the input shaft of transmission (8). The engine power is
also transmitted through the pump drive gear of the torque converter to work equipment pump (19),
cooling fan pump (20), steering pump (17), and power train pump (18) to drive those pumps.
• Transmission (8) selects one from the four gear speeds each in the forward and reverse directions by
operating the six hydraulic clutches with the directional and gear shift valves among the transmission
valves.
• Parking brake (7) is a wet-type multiple-disc brake to stop the machine. It is installed on the front side of
the output shaft and actuated by the solenoid valve which is operated with the parking brake switch.
• The power of transmission (8) is transmitted to the front and rear axles.
The power for the front side is transmitted through center drive shaft (6), flange bearing (21), and front
drive shaft (5) to front axle (1).
The power for the rear side is transmitted through rear drive shaft (9) to rear axle (14).
• The powers transmitted to front axle (1) and rear axle (14) is reduced in speed by the pinions of
differentials (2) and (13), and then transmitted to the respective sun gear shafts through the differentials.
• The power of each sun gear is further reduced in speed by final drives (4) and (11), and then transmitted
through the axle shafts to tires (10) and (22).
10-48 WA470-7
10 Structure and function
Drive shaft
• The power from the transmission output shaft is transmitted through center drive shaft (3), front drive shaft
(1), and rear drive shaft (4) to the front and rear axles.
• The relative positions of the transmission and front and rear axles change due to articulation of the
machine body, or impacts received from the road surface during traveling, or impacts during operations,
etc. The drive shafts absorb the fluctuation of their angle and length by the universal joints and flange
bearings (2) so that the power is transmitted even when the machine receives the above impacts and
when the positions of the components change.
WA470-7 10-49
10 Structure and function
Power train piping drawing
10-50 WA470-7
10 Structure and function
Transmission control
WA470-7 10-51
10 Structure and function
Transmission control
1. Machine monitor
2. Parking brake switch
3. Kickdown switch
4. Hold switch
5. Transmission cut-off and transmission cut-off set switch
6. Monitor controller
7. Transmission controller
8. Relay
9. Fuse box
10. Transmission cut oil pressure sensor
11. Brake valve
12. Directional lever and gear speed switch
13. Transmission ECMV
14. Transmission output speed sensor
Function (WA380-CN20-042-K-00-A)
10-52 WA470-7
10 Structure and function
Transmission control
WA470-7 10-53
10 Structure and function
Torque converter
1. Pilot
2. Flywheel
3. Lockup clutch housing
4. Boss
5. Turbine
6. Drive case
7. Stator
8. Pump
9. PTO gear
10. PTO drive gear (number of teeth: 97)
11. Stator shaft
12. Guide
13. Input shaft
10-54 WA470-7
10 Structure and function
Torque converter
WA470-7 10-55
10 Structure and function
Torque converter
Drive case (3), boss (9) and turbine (8) are separated and the torque converter works as an ordinary torque
converter.
Power from engine
O
Flywheel (1)
O
Clutch housing (2)
O
Drive case (3), pump (5), and PTO drive gear (6) rotate as one unit
O
Oil is used as a medium
O
Turbine (8) and boss (9)
O
Transmission input shaft (10)
• The power transmitted to PTO drive gear (6) is then transmitted through PTO gear (7) to drive the pump.
10-56 WA470-7
10 Structure and function
Torque converter
Drive case (3), boss (9), and turbine (8) are connected and the torque converter is locked up.
Power from engine
O
Flywheel (1)
O
Clutch housing (2)
O
Drive case (3), pump (5), and PTO drive gear (6) rotate as one unit
O
Lockup clutch (4)
O
Boss (9)
O
Transmission input shaft (10)
• The power transmitted to PTO drive gear (6) is then transmitted through PTO gear (7) to drive the pump.
WA470-7 10-57
10 Structure and function
Torque converter
• The oil flows through the main relief valve and its pressure is regulated to the set pressure or below by the
torque converter relief valve. It then flows in inlet port (A), goes through the oil passages of stator shaft (1)
and guide (2), and flows into pump (3).
• The oil is given centrifugal force by pump (3) and flows in turbine (4) to transfer its energy to turbine (4).
• The oil from turbine (4) is sent to stator (5) and flows into pump (3) again. However, a part of the oil flows
between turbine (4) and stator (5), and through outlet port (B) to the oil cooler to be cooled, and then
lubricates the transmission.
10-58 WA470-7
10 Structure and function
Transmission
Transmission (WA470-CF00-041-K-00-A)
WA470-7 10-59
10 Structure and function
Transmission
10-60 WA470-7
10 Structure and function
Transmission
1. Input shaft
2. Torque converter
3. F clutch
4. R clutch
5. 4th clutch
6. Rear coupling
7. Output shaft
8. Output gear (number of teeth: 52)
9. Parking brake
10. Front coupling
11. Transfer gear 2
12. Lower shaft
13. Transfer shaft 2
14. 3rd clutch
15. middle shaft
WA470-7 10-61
10 Structure and function
Transmission
10-62 WA470-7
10 Structure and function
Transmission
WA470-7 10-63
10 Structure and function
Transmission
10-64 WA470-7
10 Structure and function
Transmission
Structure (WA470-CF60-041-K-00-A)
• The transmission employs the counter-shaft, constant mesh type gear mechanism and the disc clutches
and has "forward 4-speeds and reverse 4-speeds".
• The transmission selects one rotating direction and one gear speed by fixing two of the six disc clutches
hydraulically by the operation of the ECMV in the counter-shaft type constant mesh gear mechanism.
• The transmission transmits the power received by the transmission input shaft to the output shaft by
changing the gear speed (forward 1st to 4th or reverse 1st to 4th) with any combination of the forward or
reverse clutch, and one of four speed clutches.
10-66 WA470-7
10 Structure and function
Transmission
• The oil sent from the ECMV is supplied with pressure through the oil passage of shaft (1) to the back of
piston (2), and pushes piston (2) to the right.
• Piston (2) presses plates (3) against discs (4) to stop rotation of discs (4) with the friction force between
them.
• As the internal teeth of discs (4) are meshed with clutch gear (5), shaft (1) and clutch gear (5) transmit the
power in one piece.
• The oil is drained through oil drain hole (6), but it does not affect the operation of the clutch since its
quantity is far less than the quantity of the supplied oil.
• When the oil sent from the ECMV is shut off, the oil pressure applied to the back of piston (2) decreases.
• Piston (2) is pushed back to the left by the reactive force of wave spring (7).
• The friction force between plates (3) and discs (4) is lost and shaft (1) and clutch gear (5) are released.
• When the clutch is disengaged, the oil on the back of the piston is drained by the centrifugal force through
oil drain hole (6) to prevent partial engagement of the clutch.
a Oil drain hole (6) is provided only in the 3rd and 4th clutches.
WA470-7 10-67
10 Structure and function
Transmission
10-68 WA470-7
10 Structure and function
Transmission
WA470-7 10-69
10 Structure and function
Transmission
10-70 WA470-7
10 Structure and function
Transmission
WA470-7 10-71
10 Structure and function
Transmission
10-72 WA470-7
10 Structure and function
Transmission
WA470-7 10-73
10 Structure and function
Transmission
10-74 WA470-7
10 Structure and function
Transmission
WA470-7 10-75
10 Structure and function
Transmission
10-76 WA470-7
10 Structure and function
Transmission
WA470-7 10-77
10 Structure and function
Transmission control valve
10-78 WA470-7
10 Structure and function
Transmission control valve
WA470-7 10-79
10 Structure and function
Transmission control valve
Function (WA470-CJA0-042-K-00-A)
• The oil from the pump flows through the oil filter into the transmission control valve assembly and then is
divided into the main relief circuit and clutch actuation circuit.
• The oil regulated its pressure by the main relief valve and flowed into the clutch operating circuit goes
through the last chance filter, then operates the clutch and parking brake. The oil relieved from the main
relief valve is supplied to the torque converter.
• When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to
the command current from the transmission controller to reduce the gear shifting shocks. The ECMV also
keeps the clutch pressure constant during travel.
• If the F or R, and one of the 1st to 4th clutch ECMVs are selected, the regulated oil pressure is supplied to
the selected clutches and the desired gear speed is obtained.
• The lockup ECMV is actuated when the machine travels in the 2nd, 3rd, or 4th gear speed and its travel
speed exceeds the travel speed set by the transmission controller.
• This machine uses three types of the ECMVs, which have the following identifications and differences.
Identifi-
Fill switch
Stamp on name plate cation Mark Clutches to
color Flow detection valve (operating pressure:
(A) (C) be used
MPa {kg/cm2})
(B)
Installed F, R, 1st,
L******* ― ― Not installed
(0.20 {2.0}) 2nd
Installed
Q******* Pink S Installed 3rd, 4th
(0.24 {2.45})
K******* ― ― Not installed Not installed L/U
L/U: Indicates lockup clutch ECMV.
• Table of ECMV
operation
ECMV
F R 1st 2nd 3rd 4th L/U
F1 Q Q
F2 Q Q Q
F3 Q Q Q
Gear speed
F4 Q Q Q
R1 Q Q
R2 Q Q Q
R3 Q Q Q
R4 Q Q Q
L/U: Indicates lockup clutch ECMV.
10-80 WA470-7
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV (WA470-CJJ0-
041-K-00-A)
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
Function (HM300-CJJ0-042-K-00-A)
WA470-7 10-81
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV
The proportional solenoid receives the current from the transmission controller, and this valve converts it
into oil pressure.
• Fill switch
This switch detects that the clutch is filled with oil and has the following functions.
1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with
oil.
2. Keeps outputting the signals (fill signals) to the controller to notify that the oil pressure is applied while oil
pressure is applied to the clutch.
10-82 WA470-7
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV
WA470-7 10-83
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV
• ECMV is controlled by the command current sent from the controller to the proportional solenoid and the
fill switch output signal.
The relationship among the proportional solenoid command current for ECMV, clutch input pressure, and
fill switch output signal is shown below.
10-84 WA470-7
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV
• While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).
Fill switch (5) is turned OFF at this time since the oil pressure is not applied to pressure sensing valve (4).
WA470-7 10-85
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV
• When the current flows to proportional solenoid (1) while there is no oil in the clutch, the hydraulic force
balanced with the solenoid force is applied to chamber (B) to push pressure control valve (3) to the left. As
a result, pump port (P) is connected with clutch port (A) and the oil starts filling the clutch. When the clutch
is filled with the oil, oil pressure sensing valve (4) operates and fill switch (5) is turned "ON".
10-86 WA470-7
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV
• When a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
The pressure builds up until the thrust of the solenoid is balanced with the sum of the thrust generated by
the oil pressure in clutch port and the reaction force of pressure control valve spring (2).
WA470-7 10-87
10 Structure and function
3rd, 4th clutch ECMV
a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Flow detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
Function (WA470-CJJ0-042-K-00-A)
10-88 WA470-7
10 Structure and function
3rd, 4th clutch ECMV
This switch detects that the clutch is filled with oil and has the functions explained later.
1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with
oil.
2. Keeps outputting the signals (fill signals) to the controller to notify that the oil pressure is applied while oil
pressure is applied to the clutch.
WA470-7 10-89
10 Structure and function
3rd, 4th clutch ECMV
• ECMV is controlled by the command current sent from the controller to the proportional solenoid and the
fill switch output signal.
The relation between the proportional solenoid command current for ECMV, clutch input pressure, and fill
switch output signal is shown below.
10-90 WA470-7
10 Structure and function
3rd, 4th clutch ECMV
WA470-7 10-91
10 Structure and function
3rd, 4th clutch ECMV
• While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).
Fill switch (5) is turned OFF at this time since the oil pressure is not applied to pressure sensing valve (4).
10-92 WA470-7
10 Structure and function
3rd, 4th clutch ECMV
• When a current flows in proportional solenoid (1) while the clutch piston is not pressurized, the thrust of
the solenoid pushes ball (6) to the left to throttle the drain circuit.
• Oil pressure balanced with the thrust of the solenoid is applied to chamber (B) to move pressure control
valve (3) to the left.
• The oil flows into the clutch chamber through pump port (P) and orifice (a) of flow detection valve (4).
• Differential pressure is generated between the upstream and downstream over orifice (a) of flow detection
valve (4), and then flow detection valve (4) moves to the left.
• When the clutch chamber is filled with the oil and the oil does not flow from pump port (P) to clutch port (A)
any more, the differential pressure over orifice (a) of flow detection valve (4) is lost.
• Flow detection valve (4) is pushed back to the right by the oil pressure generated by the area difference
between clutch port (A) side and drain port side of flow detection valve (4) to turn ON fill switch (5).
WA470-7 10-93
10 Structure and function
3rd, 4th clutch ECMV
• When a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
The pressure builds up until the thrust of the solenoid is balanced with the sum of the thrust generated by
the oil pressure in clutch port and the reaction force of pressure control valve spring (2).
10-94 WA470-7
10 Structure and function
Lockup clutch ECMV
A: To clutch
P: From pump
T: Drain
Dr: Drain
P1: Clutch oil pressure pickup port
• This valve is used for adjusting the clutch oil pressure to the set pressure and selecting a clutch.
Since the modulation waveform is used for the pressure application characteristics to the clutch, the
lockup clutch is engaged smoothly and the gear shift shocks are reduced. In addition, generation of a
peak torque in the power train is prevented. As a result, the operator comfort improves and the power train
durability increases.
WA470-7 10-95
10 Structure and function
Lockup clutch ECMV
10-96 WA470-7
10 Structure and function
Lockup clutch ECMV
Operation (WA380-CDT8-044-K-00-A)
• While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).
WA470-7 10-97
10 Structure and function
Lockup clutch ECMV
• When the current flows to proportional solenoid (1), the hydraulic force balanced with the solenoid force is
applied to chamber (B) to push pressure control valve (3) to the left. As a result, pump port (P) is
connected to clutch port (A) and the oil starts filling the clutch.
• When the clutch is filled with oil, the thrust of the solenoid is balanced with the sum of the thrust generated
by the oil pressure in clutch port and the reaction force of pressure control valve spring (2), thus the
pressure is adjusted.
10-98 WA470-7
10 Structure and function
Main relief and torque converter relief valve
1. Body
2. Piston
3. Torque converter relief valve
4. Piston
5. Main relief valve
A: Drain (torque converter relief)
B: Drain
C: From pump
D: Drain
E: To torque converter
P1: Main relief oil pressure pickup port
P2: Torque converter relief oil pressure pickup port
Function (WA470-CJ10-042-K-00-A)
WA470-7 10-99
10 Structure and function
Main relief and torque converter relief valve
Operation (WA380-CJ10-044-K-00-A)
Operation of main relief valve
• The oil from the hydraulic pump flows to port (C) through the filter. Then it flows to chamber (F) through
orifice (a) in main relief valve (1).
• When the oil pressure in the circuit exceeds the set pressure, the oil in chamber (F) pushes piston (2) and
the reaction force pushes main relief valve (1) leftward. This connects ports (C) and (E).
Then, the oil from the pump flows through port (E) into the torque converter.
• The oil relieved through the main relief valve flows through port (E) into the torque converter. It also flows
through orifice (b) in torque converter relief valve (3) into chamber (G).
• When the oil pressure to the torque converter exceeds the set pressure, the oil in chamber (G) pushes
piston (4) and the reaction force of the piston pushes torque converter relief valve (3) rightward to connect
ports (E) and (A).
Then, the oil in port (E) is drained through port (A).
10-100 WA470-7
10 Structure and function
Axle
Axle (HM300-DA00-001-K-00-A)
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler pipe and level plug
8. Brake oil port
9. breather
10. Brake wear gauge
11. Drain plug
12. Air bleeder
WA470-7 10-101
10 Structure and function
Axle
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port/ level plug
8. Brake oil port
9. breather
10. Brake wear gauge
11. Drain plug
12. Air bleeder
10-102 WA470-7
10 Structure and function
Differential
Differential (HM300-DC10-001-K-00-A)
1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear
WA470-7 10-103
10 Structure and function
Differential
1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear
10-104 WA470-7
10 Structure and function
Differential
Operation (WA380-DC10-044-K-00-A)
• The power from the engine is transmitted to the front and rear axles through the torque converter,
transmission, and drive shafts.
• The power to be transmitted is changed in direction 90 degrees and in transmitting speed by bevel pinion
(1) and bevel gear (5) in the axle housing, and then transmitted to sun gear shaft (2) through pinion (4).
• The power of the sun gear is further reduced in transmitting speed by the planetary gear type final drives,
and then transmitted to the axle shaft and wheels.
When machine is traveling straight
• When the machine is traveling straight, the right and left wheels rotate at the same speed. Accordingly,
pinions (4) in the differential assembly do not rotate and the power of carrier (6) is transmitted through
pinions (4) and side gears (3) to the right and left sun gear shafts (2) evenly.
WA470-7 10-105
10 Structure and function
Differential
• When the machine is turning, the right and left wheels rotate at different speeds. Accordingly, pinions (4)
and side gears (3) in the differential rotate and transmit the power of carrier (6) to right and left sun gear
shafts (2), depending on the difference in rotation speed between the right and left wheels.
10-106 WA470-7
10 Structure and function
Differential
(if equipped)
1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear
WA470-7 10-107
10 Structure and function
Differential
(if equipped)
1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear
10-108 WA470-7
10 Structure and function
Differential
Operation (WA470-DCH2-042-K-00-A)
1. Washer
2. Disc
3. Plate
4. Pressure ring
5. Cover
6. Side gear
7. Shaft
8. Pinion
9. Bevel gear
10. Case
The power from the transmission is transmitted through bevel gear (9) to case (10), pressure ring (4), shaft (7),
pinion (8), and side gears (6), and then distributed to the right and left shafts. On the back of each side gear
(6), the brake mechanism consisting of discs (2) and plates (3) is installed. It generates braking torque in
proportion to the torque transmitted from pressure rings (4) to shaft (7).
Since the braking torque restricts the rotation of side gears (6) and case (10), side gears (6) on the right and
left sides do not rotate freely and the operation of the differential is restricted.
WA470-7 10-109
10 Structure and function
Differential
<Mechanism of generating braking torque to right and left side gears (6)>
Shaft (7) is supported on the cam surfaces made on the surfaces of pressure rings (4) that are facing each
other. The power (= torque) from pressure rings (4) is transmitted to shaft (7) through the cam surfaces. Force
Fa to separate right and left pressure rings (4) is generated by inclination of the cam surfaces in proportion to
the transmitted torque.
This separating force (Fa) acts on the brakes on the back of right and left side gears (6) to generate braking
torque.
When the driving forces of the right and left wheels are balanced
[When road conditions (friction coefficient) under the right and left wheels and the loads on wheels are even
and the center of load on the bucket is not shifted]
The power from the transmission is distributed evenly by the differential gear to the right and left. Since the
tire slip limits on the right and left sides are the same under this condition, both tires slip and the differential
does not operate even if the power from the transmission exceeds the tire slip limit.
No load is applied to the brake on the back of each side gear.
10-110 WA470-7
10 Structure and function
Differential
When the driving forces of the right and left wheels are unbalanced
[When the road conditions (friction coefficient) under the right and left wheels and the loads on wheels are
uneven and either of the wheels slips more easily than the other]
Example 1. Either wheel is on soft ground during digging work
Example 2. Either wheel is on snow and the other is on asphalt during snow plowing work
Example 3. The loads on the right and left wheels are unbalanced during travel on a slope
The power from the transmission is distributed evenly by the differential gear to the right and left. If the driving
force exceeds the tire slip limit on the more slippery side, the excessive driving force is transmitted to the
brake on the opposite side (locked side) and given to the tire on the locked side through the brake on the back
of the side gear and the case.
Only when this excessive driving force exceeds the braking force, the differential operates.
Difference of wheel driving force by type of differential when either wheel slips
Wheel driving force (slipping wheel is set as 1)
Slipping wheel Locked wheel Total (ratio)
Limited Slip Differential 1 2.64 3.64 (1.82)
Conventional differential 1 1 2 (1)
On a road surface where either wheel slips easily, the Limited Slip Differential increases the driving force by
1.82 times compared to the conventional differential.
WA470-7 10-111
10 Structure and function
Differential
Since the differential gear in the Limited Slip Differential is the same as the one used in the conventional
differential, it can smoothly generate the rotational difference between the inside and outside wheels that is
caused by turning.
10-112 WA470-7
10 Structure and function
Final drive
1. Planetary gear
2. Planetary carrier
3. Axle shaft
4. Ring gear
5. Sun gear shaft
WA470-7 10-113
10 Structure and function
Final drive
Operation (WA380-DF10-044-K-00-A)
• The final drive finally reduces the speed to transmit the power from the engine and increases in drive
power.
• Ring gear (4) is press-fitted to the axle housing and fixed with the pin.
• The power transmitted from the differential through sun gear shaft (5) is reduced in speed and increased
in drive power by the planetary gear mechanism.
• The increased drive power is transmitted through planetary carrier (2) and axle shaft (3) to the wheels.
10-114 WA470-7
10 Structure and function
Layout of steering parts
WA470-7 10-115
10 Structure and function
Steering column
1. Steering wheel
2. Steering column
3. Steering tilt lock lever
4. Short column
5. Orbit-roll valve
10-116 WA470-7
10 Structure and function
Steering pump
WA470-7 10-117
10 Structure and function
Steering pump
10-118 WA470-7
10 Structure and function
Steering pump
1. Bearing
2. Shaft
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
WA470-7 10-119
10 Structure and function
Steering pump
Structure
• Cylinder block (6) is supported by spline (a) on shaft (1).
• Shaft (1) is supported by each bearing at the front and rear.
• The tip of piston (5) shapes a spherical concave and integrates with shoe (4) by gripping it.
• Piston (5) and shoe (4) form a spherical bearing.
• Rocker cam (3) is supported by case (2) and ball retainer (9) and has flat surface (A), and shoe (4) is
always pressed against this surface while sliding in a circular pattern.
• Shoe (4) leads high-pressure oil to form a static pressure bearing for its sliding.
• Piston (5) moves relatively in the axial direction in each cylinder chamber of cylinder block (6).
• Cylinder block (6) rotates relatively to valve plate (7) while sealing the pressurized oil.
• This plane is designed so that the oil pressure is balanced correctly.
• The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (6)
through valve plate (7).
Specifications (WA470-F220-030-K-00-A)
Model LPV90
Type Variable displacement swash plate type piston pump
Theoretical delivery (cm3/rev) 90
Rated delivery pressure: (MPa {kg/
24.5 {250}
cm2})
Rated speed (rpm) 2,280
Function (WA380-F220-042-K-00-A)
• The engine rotation and torque transmitted to the pump shaft is converted into the hydraulic energy and
the pressurized oil corresponding to the load is discharged.
10-120 WA470-7
10 Structure and function
Steering pump
• Cylinder block (6) rotates together with shaft (1) and shoe (4) slides on plane (A).
• Rocker cam (3) pivots on ball retainer (9), and accordingly angle (a) between center line (X) of rocker cam
(3) and the axis of cylinder block (6) changes.
• Angle (a) is called the swash plate angle.
• While angle (a) is made between center line (X) of rocker cam (3) and the axis of cylinder block (6), plane
(A) works as a cam for shoe (4).
• Piston (5) reciprocates inside cylinder block (6) and a difference is made between volumes (E) and (F) of
the cylinder chamber in cylinder block (6).
• Oil in amount of (F) minus (E) is sucked in and discharged from piston (5).
• Oil is discharged while cylinder block (6) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (F) increases.
• In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge
stroke.
WA470-7 10-121
10 Structure and function
Steering pump
• When center line (X) of rocker cam (3) matches the axis of cylinder block (6) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (6) is zero.
• Suction and discharge of pressurized oil is not performed in this stage. Namely pumping action is not
performed. (Actually, however, a zero swash plate angle never occurs.)
• The pump delivery is in proportion to swash plate angle (a).
Control of delivery
• When swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
delivery (Q) is increased.
• Swash plate angle (a) is changed by servo piston (11).
• Servo piston (11) reciprocates linearly according to the signal pressure from the PC valve and LS valve.
• This linear motion is transmitted to rocker cam (3).
• Being supported by ball retainer (9) on case (2), rocker cam (3) slides in the direction of rotary movement.
10-122 WA470-7
10 Structure and function
Steering pump
WA470-7 10-123
10 Structure and function
Steering pump
PC valve
T: Drain
PA: Pump pressure input
PPL: PC valve output pressure
PM: PC mode selector pressure
1. Lever
2. Spring
3. Retainer
4. Seat
5. Spool
6. Sleeve
7. Piston
8. Seal
9. Piston
LS valve
10-124 WA470-7
10 Structure and function
Steering pump
LS valve (WA380-F2R0-001-K-00-A)
Function (WA380-F2R0-042-K-00-A)
• The LS valve controls the pump delivery according to the travel of the control lever, or the flow demanded
by the actuator.
• The LS valve detects the flow rate demanded by the actuator from differential pressure (dPLS) between
inlet pressure (PPLS) and outlet pressure (PLS) of the control valve and controls pump delivery (Q) of the
main pump. [(PPLS) is called the LS pump pressure, (PLS) the LS pressure, and (dPLS) the LS
differential pressure.]
• In other words, pressure loss [= LS differential pressure (dPLS)], which occurs when oil flows through the
passage in control valve spool, is detected, and pump delivery (Q) is controlled to maintain the pressure
loss at a constant level. Through this operation, pump can deliver the proper volume of oil as demanded
by the actuator.
• Main pump delivery pressure (PP), LS pump pressure (PPLS) and LS pressure (PLS) are transmitted into
the LS valve. Pump delivery (Q) changes as shown in the following figure according to the LS differential
pressure (dPLS).
WA470-7 10-125
10 Structure and function
Steering pump
PC valve (WA380-F2S0-001-K-00-A)
Function (WA380-F2S0-042-K-00-A)
• The PC valve limits the oil flow to a certain level (depending on the delivery pressure) even if the travel of
the control valve is increased extremely so that the horsepower absorbed by the pump does not exceed
the engine horsepower, when pump delivery pressure (PA) is high.
• In other words, the PC valve decreases the pump delivery when the actuator load is increased and the
pump delivery pressure rises, and increases it when the pump delivery pressure lowers.
• If command current (X) sent to EPC valve increases further, the relationship between pump pressure (PP)
and pump delivery (Q) is shifted parallel in proportion to the thrust of EPC valve solenoid.
• That is, since the thrust of the EPC valve solenoid is added to the left-hand thrust caused by the pump
pressure applied to spool (6), the relationship between pump pressure (PA) and (Q) is shifted from [1] to
[2] as (X) increases.
Operation (WA380-F2S0-044-K-00-A)
Action of spring
• The spring force of spring (3) in the PC valve is determined by the angle of the swash plate.
• When servo piston (9) moves to the right, spring (3) is compressed through lever (2) and the spring force
changes.
10-126 WA470-7
10 Structure and function
Steering pump
• Accordingly, the stop position (= pump delivery) of servo piston (9) is determined by the position where the
thrust caused by pressure (PA) applied to piston (10) is balanced with the spring force of spring (3) acting
through spool (6). (Fig. 3)
WA470-7 10-127
10 Structure and function
Steering pump
10-128 WA470-7
10 Structure and function
Steering valve
WA470-7 10-129
10 Structure and function
Steering valve
1. Relief valve
2. Flow control spool
3. Steering relief valve
4. Steering spool
5. Overload relief valve
10-130 WA470-7
10 Structure and function
Steering valve
Operation (WA380-F570-044-K-00-A)
Operation of flow amplifier
• Since ports (Pa) and (Pb) are connected to the drain circuit through the orbit-roll valve, steering spool (1)
is held in the neutral position by right and left return springs (2).
• The pressure in port (Pa) increases and steering spool (1) compresses left return spring (2) and moves to
the left.
• The oil in port (Pa) flows through the hole of spring seat (3) and orifice (a) of steering spool (1) to port (Pb).
• Since port (Pb) is connected to the drain circuit through the orbit-roll valve, the oil in port (Pb) is drained.
• Since the pressure generated in port (Pa) is in proportion to the oil flow, steering spool (1) moves to a
position in which the oil pressure reduced by orifice (a) is balanced with the reaction force of return spring
(2).
WA470-7 10-131
10 Structure and function
Steering valve
• Since ports (Pa) and (Pb) are connected to the drain circuit through the orbit-roll valve, steering spool (1)
is returned to the neutral position by left return springs (2).
10-132 WA470-7
10 Structure and function
Steering valve
• When steering spool (2) operates, notch (f) closes to disconnect pressure receiving chamber (Y) and port
(T1), and notch (e) opens.
• The oil pressure in pressure receiving chamber (Y) increases, flow control spool (1) moves to the right,
and the open area of notch (d) decreases.
• The oil before passing through notch (e) is led to pressure receiving chamber (X) and the oil after passing
through notch (e) is led to pressure receiving chamber (Y).
• When the oil pressure in pressure receiving chamber (Y) exceeds that in port (A), the oil flowing in through
orifice (h) pushes load check valve (3) open to the left.
• Since the oil from notch (e) flows through port (A) to the steering cylinder, pressure difference is made
before and after notch (e).
• Since flow control spool (1) operates to maintain the differential pressure generated over notch (e) to the
set pressure, oil is delivered to the steering cylinder according to the open area of notch (e).
• The excessive oil from the steering pump is drained through orifice (d) and port (T1).
• The return oil from the steering cylinder is drained through orifice (g) and port (T1).
• Even if flow control spool (1) moves to the right until notch (d) is closed, it moves further to the right if the
pressure before notch (e) is below the set pressure.
• Since the open area of notch (c) is narrowed and the oil flow to port (Pr) is reduced, the oil pressure in port
(Pr) decreases.
• When the oil pressure in port (Pr) decreases, the LS valve of the steering pump increases its delivery to
maintain the oil pressure in port (Pr) at the set pressure.
• Flow control spool (1) is held in a position where the pressure in port (P) is balanced with the pressure in
port (Pr), and the pump delivery is kept constant.
WA470-7 10-133
10 Structure and function
Steering valve
• If the open area of notch (e) changes, the steering pump delivers oil according to the open area of notch
(e) to keep the oil pressure in port (Pr) constant.
When in neutral
• Since the steering wheel is not operated, steering spool (1) does not move.
• The oil from the steering pump flows in port (P).
• When the oil pressure in port (P) increases, flow control spool (2) moves to the left to drain the oil from the
steering pump through notch (a) and port (T1).
10-134 WA470-7
10 Structure and function
Steering valve
• When the steering wheel is turned to the left, the output pressure from the orbit-roll valve enters port (Pa)
and steering spool (1) is pushed to the right.
• The oil from the steering pump enters port (P) and flows through flow control spool (2) to steering spool
(1).
• Load check valve (3) is pushed open to the left and the oil flows to the head side of the left steering
cylinder and to the bottom side of the right steering cylinder to turn the machine to the left.
• The return oil from the right and left steering cylinders is drained through load check valve (4) and port
(T1).
WA470-7 10-135
10 Structure and function
Steering valve
• When the steering wheel is turned to the right, the output pressure from the orbit-roll valve enters port (Pb)
and steering spool (1) is pushed to the left.
• The oil from the steering pump enters port (P) and flows through flow control spool (2) to steering spool
(1).
• Load check valve (4) is pushed open to the right and the oil flows to the head side of the right steering
cylinder and to the bottom side of the left steering cylinder to turn the machine to the right.
• The return oil from the right and left steering cylinders is drained through load check valve (3) and port
(T1).
10-136 WA470-7
10 Structure and function
Steering valve
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function (WA380-F590-042-K-00-A)
• The steering relief valve is installed to the steering valve and maintains the oil pressure in the steering
circuit at the set pressure during steering operation.
WA470-7 10-137
10 Structure and function
Steering valve
Operation (WA380-F590-044-K-00-A)
• If the oil pressure in the steering circuit increases to the pressure set with adjustment screw (1) and spring
(2), pilot poppet (3) opens to drain the oil through port (T1).
• Pressure receiving chambers (X) and (Y) are unbalanced in pressure and flow control spool (4) moves to
the left.
• Flow control spool (4) operates to drain the oil from the steering pump and maintain the steering circuit
pressure below the set value.
10-138 WA470-7
10 Structure and function
Steering valve
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function (WA380-F5B0-042-K-00-A)
• The overload relief valve is installed to the steering valve and protects the cylinder circuit from abnormally
high pressure generated by impacts applied to the cylinder for some reason while the steering valve is in
neutral.
• If abnormally high pressure is generated on the cylinder side, this valve works as a safety valve to prevent
breakage of the cylinder and hydraulic piping.
• If negative pressure is generated on the cylinder side, this valve works as a suction valve to prevent a
vacuum in the circuit.
WA470-7 10-139
10 Structure and function
Steering valve
Operation (WA380-F5B0-044-K-00-A)
• Port (A) is connected to the cylinder circuit and port (B) is connected to the drain circuit.
• The oil flows through the hole of poppet (1) to the inside of relief valve poppet (2).
• Check valve poppet (3) and relief valve poppet (2) are securely seated because of the area difference
between diameters (d1) and (d2).
• If the oil pressure in port (A) exceeds the set pressure of the relief valve, pilot poppet (4) is moved open to
the right.
• The oil flows through pilot poppet (4) and drill hole to port (B).
• Since pilot poppet (4) opens, the oil pressure inside poppet (1) lowers.
• Poppet (1) moves to the right to seat pilot poppet (4).
10-140 WA470-7
10 Structure and function
Steering valve
• The oil pressure inside relief valve poppet (2) is lower than the oil pressure in port (A).
• Since the oil pushes open relief valve poppet (2) to the right and flows from port (A) to port (B), the circuit
is protected from abnormally high pressure.
• If negative pressure is generated in port (A), it acts on the area difference between diameters (d3) and
(d4) and pushes check valve poppet (3) to the right.
• The oil flows from port (B) to port (A) to prevent a vacuum.
WA470-7 10-141
10 Structure and function
Steering valve
1. Plug
2. Spring
3. Valve
4. Valve seat
Function (WA380-F530-042-K-00-A)
• The relief valve is installed to the steering valve and relieves the oil when the oil pressure in port (Pr)
exceeds the set pressure to protect the LS circuit of the steering pump from abnormally high pressure.
10-142 WA470-7
10 Structure and function
Orbit-roll valve
WA470-7 10-143
10 Structure and function
Orbit-roll valve
10. Spacer
11. End cap
Outline
• The orbit-roll valve is connected directly to the drive shaft of the steering column, and sends the oil from
the steering pump to the right or left steering cylinder to change the travel direction of the machine.
• The orbit-roll valve roughly consists of two sections; One is the section of spool (9) and sleeve (8) which
has rotary-type direction selection function, and the other is gerotor (5) (combination of rotor (5a) and
stator (5b)) which works as a hydraulic motor during the normal steering operation but works as a hand
pump when no oil is supplied because of a steering pump failure or an engine failure (however, it cannot
be operated actually since its operating effort is too high).
10-144 WA470-7
10 Structure and function
Orbit-roll valve
Structure
• Top (A) of spool (9) is connected to the drive shaft of the steering column and further connected to sleeve
(8) by center pin (7) (which does not touch spool (9) when the steering wheel is in "neutral") and centering
spring (2).
• Drive shaft (3) is meshed at top (B) with center pin (7) and forms one unit with sleeve (8). Its bottom is
meshed with the spline of rotor (5a) of gerotor (5).
• Valve body (4) has four ports, which are connected respectively to the pump circuit, tank circuit, left
steering circuit, and right steering circuit. The ports on the pump and tank are connected through the
check valve inside the body. If the pump or the engine is failed, the oil can be sucked in directly from the
tank through this check valve.
WA470-7 10-145
10 Structure and function
Orbit-roll valve
• The above figure shows the connections of suction and discharge ports (P) of the gerotor and the sleeve
ports.
• When the steering wheel is turned to the right, ports (a), (c), (e), (g), (i) and (k) are connected by the
vertical grooves in the spool to the pump. At the same time, ports (b), (d), (f), (h), (j) and (l) are connected
to the head side of the right steering cylinder in the same way.
In the condition shown in Fig. 1, ports (1), (2) and (3) are the discharge ports of the gerotor and connected
to ports (l), (b) and (d) to send the oil to the steering cylinder.
Ports (5), (6) and (7) are also connected to each other and the oil flows in from the pump.
Fig. 2 shows the condition after the steering wheel is turned 90° from the above condition. Under this state,
ports (2), (3) and (4) are in the suction condition and connected to ports (k), (a) and (c). Ports (5), (6) and
(7) are in the discharge condition and connected to ports (d), (f) and (h).
• In this way, the ports of the gerotor in the discharge condition are connected to the ports connected to the
steering cylinder. The ports in the suction condition are connected to the pump circuit.
• For every 1/7 turn of the steering wheel, the inner teeth of the gerotor gear advance one position to deliver
oil from the pump by the quantity for this operation.
Accordingly, the quantity of the oil delivered from the pump is directly proportional to the turning angle of
the steering wheel.
10-146 WA470-7
10 Structure and function
Orbit-roll valve
• Centering spring (2) is composed of layers of two flat leaf springs and four X-shaped leaf springs and
installed between spool (9) and sleeve (8) as shown in the figure.
WA470-7 10-147
10 Structure and function
Orbit-roll valve
• When the steering wheel is turned, spool (9) compresses the centering spring and angular displacement
(a) is generated between spool (9) and sleeve (8).
As a result, the ports in spool (9) and sleeve (8) are connected and the oil is sent to the steering cylinder.
When the steering wheel is stopped turning, the gerotor also stops turning, and accordingly no more oil is
sent to the steering cylinder and the oil pressure rises.
To prevent this, when the steering wheel is stopped turning, centering spring (2) rotates spool (9) by the
turning angular displacement (a) from sleeve (8) to return the steering wheel to the neutral condition.
10-148 WA470-7
10 Structure and function
Stop valve
WA470-7 10-149
10 Structure and function
Emergency steering motor
(if equipped)
1. Terminal E
2. Terminal M
Function (WA380-F9R0-042-K-00-A)
• The emergency steering motor drives the emergency steering pump according to the signals from the
transmission controller when the steering circuit pressure decreases abnormally.
Specification (WA380-F9R0-030-K-00-A)
Name DC motor
Rated voltage (V) 24
Rated output (KW) 0.9
10-150 WA470-7
10 Structure and function
Emergency steering pump
(if equipped)
Specification (WA380-F940-030-K-00-A)
Function (WA380-F940-042-K-00-A)
• The emergency steering pump is installed together with the emergency steering motor to the right side of
the transmission. It supplies oil to the steering circuit if the engine stops or the steering circuit pressure
decreases below the specified value.
WA470-7 10-151
10 Structure and function
Layout of brake parts
10-152 WA470-7
10 Structure and function
Layout of brake parts
WA470-7 10-153
10 Structure and function
Charge valve
P: From pump
A: To cooling fan motor
PPC: To Orbitrol valve or work equipment valve or EPC valve of each pump
ACC1: To brake valve port PA
ACC2: To brake valve port PB
T: Drain
G: Accumulator charge pressure pickup port
10-154 WA470-7
10 Structure and function
Charge valve
1. Valve body
2. Sequence valve (H1)
3. Relief valve (R2)
4. Shuttle valve (S1)
5. Priority valve
6. PPC relief valve (R3)
7. Main relief valve (R1)
Function (WA380-G2H0-042-K-00-A)
• The charge valve maintains the oil pressure from the pump at the set pressure and saves the pressure in
the accumulator.
• When the pressure is saved in the accumulator, the circuit to the cooling fan motor opens to output the
pressurized oil from the pump to drive the cooling fan motor.
• When the oil pressure rises above the specified pressure, the oil from the pump is led to the drain circuit to
reduce the load on the pump.
• The charge valve reduces the oil from the pump in pressure and outputs the source pressure for the pilot
circuit.
WA470-7 10-155
10 Structure and function
Charge valve
Operation (WA380-G2H0-044-K-00-A)
When oil is not supplied to accumulator (cut-out condition)
• Since the pressure in oil passage (B) is higher than the set pressure of relief valve (1), piston (2) is pushed
forcibly to the right by the pressurized oil from oil passage (B).
• Relief valve (1) opens, and oil passage (C) and port (T) are interconnected.
• The pressurized oil from the pump flows through orifices (a) and (b) and oil passage (C) to port (T).
• Since the pressure drops when it passes orifice (a), pressure difference is generated between pressure
receiving chambers (D) and (E).
• When the pressure in pressure receiving chamber (D) exceeds the set pressure of priority valve (5),
priority valve (5) compresses spring (6) and moves to the right.
• The open areas of port (P) and orifice (c) are narrowed and port (P) starts to be interconnected to port (A).
• The pressurized oil from the pump flows through port (P), sequence valve (7), and port (A) to the cooling
fan motor.
When oil is supplied to accumulator (Cut-in condition)
• When the pressure in oil passage (B) decreases below the set pressure of relief valve (1), relief valve (1)
is returned to the left by the reaction forces of springs (3) and (4).
10-156 WA470-7
10 Structure and function
Charge valve
• Relief valve (1) closes, and oil passage (C) and port (T) are disconnected.
• Since oil passage (C) and port (T) are disconnected, the pressure drops less when it passes orifice (a)
and the pressure difference between pressure receiving chambers (D) and (E) decreases.
• Priority valve (5) is moved to the left by the reaction force of spring (6).
• The open areas of port (P) and orifice (c) are increased and port (P) starts to be disconnected from port
(A).
• When the oil pressure from the pump exceeds the pressure of ports (ACC1) and (ACC2), it pushes up
check valve (8) and pressure starts being saved in the accumulator through ports (ACC1) and (ACC2).
• A certain quantity of oil decided by the size (area) of orifice (c) and the pressure difference over orifice (c)
(equivalent to force of spring (6)) is supplied through ports (ACC1) and (ACC2) to the accumulator. The
excess oil flows to ports (A) and (PPC).
• When the pressure in oil passage (C) reaches the set pressure of relief valve (1), relief valve (1) is pushed
to the right by the oil pressure from oil passage (C).
• Relief valve (1) opens, and oil passage (C) and port (T) are interconnected.
• Pressure difference is generated between the right and left sides of piston (2), and then piston (2) moves
to the right to open relief valve (1) forcibly.
• Since pressure receiving chamber (E) of priority valve (5) is also connected to oil passage (C), the
pressure in pressure receiving chamber (E) becomes the drain pressure.
• Since the pressure in pressure receiving chamber (D) decreases to the level for the force of spring (6), oil
supply to oil passage (B) stops.
Main relief valve (R1)
• When the pressure in port (P) (pump pressure) exceeds the set pressure, it compresses spring (1) and
moves ball (2) to the left.
WA470-7 10-157
10 Structure and function
Charge valve
• The pressurized oil from the pump reduces in pressure when it passes through orifice (a). As a result, the
pressure difference compresses spring (3) and moves valve (4) to the left largely.
• Since ports (P) and (T) are connected to drain the pump pressure, the maximum pressure of the charge
circuit is limited to protect the circuit.
PPC relief valve (R3)
• When the pressure in port (PPC) (pilot pressure) exceeds the set pressure, the pressurized oil from the
pump compresses spring (1) and moves ball (2) to the left.
• The pressurized oil from the pump reduces in pressure when it passes through orifice (a). As a result, the
pressure difference compresses spring (3) and moves valve (4) to the left.
• The open area between ports (PPC) and (P) decreases and causes pressure drop. As a result, the
pressure in port (P) does not decrease to the set pressure of the PPC relief valve but is maintained.
• The pressure in port (PPC) is maintained at a certain value of pressure by adjusting the open area
between ports (PPC) and (P) and supplied as the source pressure of the pilot pressure.
• When the pressure in port (PPC) becomes abnormal, port (PPC) and port (T) are interconnected to
release the abnormal pressure and protect the pilot circuit.
Sequence valve (H1)
• The pressure of port (P) (pump pressure) is applied to the left end of sequence valve (1) and the drain
pressure is applied to the right end.
• When the pump pressure exceeds the set pressure of spring (2), sequence valve (1) moves to the right to
interconnect ports (P) and (A).
• The pressurized oil from the pump flows through priority valve (3) and port (A) to the cooling fan motor to
drive the motor.
• Even when the driving pressure of the cooling fan motor is low, the sequence valve maintains the pump
pressure above the set pressure of spring (2) and prevents the accumulator charge pressure and the
source pressure of the pilot circuit from decreasing.
10-158 WA470-7
10 Structure and function
Charge valve
• When the pressure in port (ACC1) is higher than the pressure in port (ACC2), shuttle valve (1) moves to
the left to disconnect port (ACC1) and oil passage (B).
• The open area between port (ACC2) and oil passage (B) increases and the oil is supplied to the
accumulator on the port (ACC2) side.
• When the pressure in port (ACC2) is higher than port (ACC1), the oil is supplied to the accumulator on the
port (ACC1) side.
• The pressurized oil from the pump is supplied first to the lower pressure circuit of the two systems.
WA470-7 10-159
10 Structure and function
Brake valve
• The brake valve is installed to the front lower part of the operator's seat. When the brake pedal is
depressed, the oil flows to the brake piston to operate the brake.
• The right and left brake pedals are connected mechanically. When either of them is depressed, the other
one is operated, as well.
• If the brake pedal is depressed, the transmission cut-off oil pressure sensor operates and supplies signals
to the transmission controller to set the transmission in neutral electrically.
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10 Structure and function
Brake valve
Operation (WA380-G2B0-044-K-00-A)
When brake pedal is depressed
• When brake pedal (1) is depressed, the depressing force is transmitted to spool (5) through rod (2), piston
(3), and spring (4).
• When spool (5) is pushed to the right, port (TA) is closed and the oil from the pump flows through the
accumulator to port (PA) and further flows through port (A) to the rear brake piston to operate the rear
brake.
• At the same time when spool (5) is moved to the right, spool (6) is also moved to the right to close port
(TB). Then, the oil from the pump flows through the accumulator to port (PB) and further flows through port
(B) to the front brake piston to operate the front brake.
• Even if the front or rear brake system has trouble such as oil leakage and only either of them operates, the
depressing force of brake pedal (1) moves spools (5) and (6) to the right mechanically.
Accordingly, the oil from the pump flows to the normal brake piston to apply the brake as usual, thus the
machine can be stopped and the safety is kept high.
WA470-7 10-161
10 Structure and function
Brake valve
Balancing operation
• When the oil fills the rear brake piston and the pressure between ports (PA) and (A) increases, the oil
flowing in chamber (E) through orifice (c) of spool (5) pushes spool (5) back to the left against the reaction
force of spring (4) to disconnect port (PA) from port (A).
At this time, port (TA) is kept closed to maintain the oil in the brake piston and leave the brake applied.
• At the same time when spool (5) moves to the left, the oil also fills the front brake piston and the pressure
between ports (PB) and (B) increases, and the oil flowing in chamber (F) through orifice (d) of spool (6)
pushes back spool (6) to the left by the distance of movement of spool (5) to disconnect port (PB) from
port (B).
Port (TB) is kept closed to maintain the oil in the brake piston and leave the brake applied.
• The oil pressure in the rear brake circuit [on port (A) side] is balanced with the depressing force of the
brake pedal, and the oil pressure in the front brake circuit [on port (B) side] is balanced with the oil
pressure in the rear brake circuit [on port (A) side].
When spools (5) and (6) are moved to the right stroke end, the line between port (PA) and (A) and that
between port (PB) and (B) are open fully, and the oil pressures in the rear and front brake circuits are
equal to the oil pressure from the pump.
Accordingly, the braking force can be adjusted by adjusting the depressing force of the brake pedal until
spools (5) and (6) move to the right stroke end.
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10 Structure and function
Brake valve
• If brake pedal (1) is released, the depressing force of the pedal applied to spool (5) is released.
• When spool (5) is pushed back to the left by the back pressure on the rear brake piston and the reaction
force of spring (7), port (PA) is closed and the oil in the rear brake piston flows through port (A) to port (TA),
and then is drained into the hydraulic tank through port (TB), and the rear brake is released.
• At the same time when spool (5) is moved to the left, spool (6) is also pushed back to the left by the back
pressure on the front brake piston and the reaction force of spring (7), and port (PB) is closed and the oil in
the front brake piston flows through port (B) to port (TB), and then is drained into the hydraulic tank, and
the front brake is released.
WA470-7 10-163
10 Structure and function
Slack adjuster
A: Inlet port
B: Outlet port
1. Cylinder
2. Check valve
3. Piston
4. Spring
5. Bleeder
Specifications (WA470-G310-030-K-00-A)
Function (WA470-G310-042-K-00-A)
• The slack adjuster is installed in the brake oil line going to the brake piston from the brake valve, and
keeps the time lag in braking operation at a constant value.
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10 Structure and function
Slack adjuster
Operation (WA470-G310-044-K-00-A)
1. When brake pedal is depressed
• Before the brake pedal is depressed, pistons (4) are returned by stroke (S) (full stroke). When the brake
pedal is depressed, the oil from the brake valve is divided at slack adjuster port (P) and flows to the right
and left cylinders (2) to move pistons (4) rightward and leftward by stroke (S).
• As a result, brake piston (6) moves by stroke (S). At this time, the clearance between brake piston (6) and
disc becomes zero, but no braking force is generated.
• When the brake pedal is depressed further and the oil pressure from the brake valve exceeds the
specified pressure, check valve (3) opens and pressure is applied to port (C) to generate braking force.
Thus, the time lag when the brake is applied is maintained constant.
WA470-7 10-165
10 Structure and function
Slack adjuster
• When the brake pedal is released, piston (4) is returned by return spring (7) of brake piston (6) for the oil
amount equivalent to stroke (S) and the brake is released. That is, return stroke (T) of brake piston (6) is
decided by the oil amount for piston stroke (S) of the slack adjuster and the time lag in braking is kept
constant, regardless of wear of the brake disc.
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10 Structure and function
Accumulator (for brake)
1. Plug
2. Gas valve
3. Top cover
4. Cylinder
5. Free piston
6. End cover
Specifications (WA380-G2G0-030-K-00-A)
Function (WA380-G2G0-042-K-00-A)
• The accumulator is installed between the charge valve and brake valve. The space between cylinder (4)
and free piston (5) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulsation generated
by the hydraulic pump by utilizing its compressibility, and secures the braking force and operability when
the engine is stopped.
WA470-7 10-167
10 Structure and function
Brake
Brake (HM300-G160-001-K-00-A)
Front (WA470-G16H-041-K-00-A)
1. Differential housing
2. Carrier
3. Piston
4. Spring
5. Plate
6. Sun gear shaft
7. Axle housing
8. End plate
9. Disc
Structure
• The front brake is a wet-type multiple-disc brake, which consists of piston (3), plate (5), disc (9), end plate
(8), and spring (4).
• The brake cylinder consists of differential housing (1) and carrier (2), and piston (3) is installed in it.
Plate (5) and end plate (8) are engaged with the spline of differential housing (1).
• Disc (9) has linings stuck to its both sides and is installed between plate (5) and end plate (8), and
engaged with the spline of sun gear shaft (6).
10-168 WA470-7
10 Structure and function
Brake
Rear (WA470-G16K-041-K-00-A)
1. Differential housing
2. Carrier
3. Piston
4. Spring
5. Plate
6. Sun gear shaft
7. Axle housing
8. End plate
9. Disc
Structure
• The rear brake is a wet-type multiple-disc brake, which consists of piston (3), plate (5), disc (9), end plate
(8), and spring (4).
• The brake cylinder consists of differential housing (1) and carrier (2), and piston (3) is installed in it.
Plate (5) and end plate (8) are engaged with the spline of differential housing (1).
• Disc (9) has linings stuck to its both sides and is installed between plate (5) and end plate (8), and
engaged with the spline of sun gear shaft.
WA470-7 10-169
10 Structure and function
Brake
Operation (WA380-G160-044-K-00-A)
When brake is applied
• When the brake pedal is depressed, pressurized oil (P) supplied from the hydraulic tank through the pump
and brake charge valve flows through the oil passage in the brake cylinder to pushes piston (2) to the left.
Accordingly, discs (4) held between piston (2), plates (3), and end plate (5) are locked and the machine is
braked.
When brake is released
• When the oil pressure is released, piston (2) is returned by the reaction force of spring (8). As a result,
clearance is made between plate (3) and end plate (5), and the brake is released.
The linings stuck to discs (4) are grooved in a check pattern, and oil flows in the grooves to cool the linings
while discs (4) are turning.
10-170 WA470-7
10 Structure and function
Parking brake control
Outline
• Parking brake (4) is a wet-type multiple-disc brake built in the transmission, which is installed in the output
shaft bearing area, operated mechanically with the pressing force of the spring, and released hydraulically.
• When parking brake switch (1) installed in the operator's compartment is turned "ON", parking brake
solenoid valve (3) installed to the valve assembly blocks the hydraulic oil, and consequently parking brake
(5) operates.
• When parking brake switch is turned "OFF", the hydraulic pressure of the cylinder releases parking brake
(5).
• While the parking brake is applied (the solenoid valve is in "OFF"), the neutralizer signal blocks the signals
from the transmission controller to the transmission solenoid valve to keep the transmission in neutral.
• Parking brake emergency release valve (2) is installed to move the machine when it stops because of a
trouble in the engine or drive system (the parking brake is applied).
WA470-7 10-171
10 Structure and function
Parking brake
1. Output shaft
2. Spring (outside)
3. Spring (inside)
4. Parking brake oil port
5. Piston
6. Plate
7. Disc
8. Wave spring
Structure
• The parking brake is a wet-type multiple-disc brake, which is operated mechanically by springs (2) and (3)
to brake output shaft (1).
Operation (WA380-GJ20-044-K-00-A)
• When the brake is applied, piston (5) presses plates (6) and discs (7) against each other with the tension
of springs (2) and (3) to lock output shaft (1).
• When the brake is released, the oil pressure from parking brake oil port (4) moves piston (5) to release the
pressing force on discs (7) and plates (6).
10-172 WA470-7
10 Structure and function
Parking brake solenoid valve
WA470-7 10-173
10 Structure and function
Parking brake solenoid valve
Operation (WA380-GJD0-044-K-00-A)
When parking brake is applied (solenoid is de-energized)
• When the parking brake switch is turned "ON", coil (1) is "de-energized" and spool (2) is moved down by
the reaction force of spring (3).
• Pump port (P) and parking brake port (A) are closed and the pressurized oil from the pump does not flow
to the parking brake. At this time, the oil that is operating the parking brake flows through port (A) to port
(T) and is drained.
• Since the oil that is operating the piston is drained, the piston pushed back by the spring presses the
plates and discs to apply the brake.
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10 Structure and function
Parking brake solenoid valve
• When the parking brake switch is turned "OFF", coil (1) is "energized" and spool (2) moves up.
• The pressurized oil from the pump enters port (P) and flows around spool (2) and through port (A) to the
parking brake. At the same time, port (T) closes and the oil is not drained.
• Since the oil pressure is applied to the piston, the piston compresses the spring and separates the plates
and discs to release the parking brake.
WA470-7 10-175
10 Structure and function
Parking brake emergency release valve
A: From accumulator
B: To parking brake solenoid valve
1. Grip
2. Valve
Function (WA380-GJG0-042-K-00-A)
• The parking brake emergency relief valve is installed between the accumulator of the brake circuit and
parking brake solenoid. When the oil pressure from the power train pump cannot be supplied because of
an engine trouble etc., the accumulator charge pressure of the brake circuit can be supplied to the parking
brake cylinder by opening this valve manually.
10-176 WA470-7
10 Structure and function
Axle mount and center hinge pin
1. Front axle
2. Front frame
3. Rear axle
4. Rear frame
Function (WA380-H1K0-042-K-00-A)
• Front frame (2) and rear frame (4) are connected by the center hinge pin with the bearing between them.
The right and left steering cylinders connecting front frame (2) and rear frame (4) adjust the articulate
angle of the frames, or the turning radius, by extending and retracting their piston rods.
WA470-7 10-177
10 Structure and function
Tire
Tire (WA470-DW60-041-K-00-A)
Radial tire
Structure
• The cords composing carcass (1) are arranged at right angles (radially) to the center line of tread (T).
• Tread (T) is stabilized and protected by several strong belts (2).
• Side wall (W) and tread (T) are independent structurally from each other.
Gripping characteristics
• Even when the tire is deflected by the load, it makes little unnecessary movement and grips the ground
stably and securely.
Deflection characteristics
• When the tire is loaded, only its side wall (W) is deflected and tread (T) composed of strong belts (2)
maintains independent stability.
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10 Structure and function
Tire
Bias tire
Structure
• The cords composing carcass (1) are arranged diagonally (bias) to the center line of tread (T).
• Side wall (W) and tread (T) are made integrally.
Gripping characteristics
• When the tire is deflected by the load, its ground contact face is deflected and it makes unnecessary
movement. Accordingly, the ground contact face becomes unstable.
Deflection characteristics
• When the tire is loaded, side wall (W) and tread (T) move as one piece.
WA470-7 10-179
10 Structure and function
Hydraulic component layout
10-180 WA470-7
10 Structure and function
Hydraulic component layout
2. Bucket cylinder
3. Control valve
4. Work equipment lock solenoid valve
5. Steering valve
6. Orbitrol valve
7. Stop valve (R.H.)
8. Brake valve
9. Cooling fan and brake pump
10. Work equipment pump
11. Hydraulic tank
12. Power train oil cooler
13. Hydraulic oil cooler
14. Cooling fan motor
15. Slack adjuster (rear)
16. Steering pump
17. Double type gear pump (power train charge pump and power train lubrication pump)
18. Emergency steering motor (if equipped)
19. Emergency steering pump (if equipped)
20. Stop valve (L.H.)
21. ECSS accumulator
22. Steering cylinder (L.H.)
23. Steering cylinder (R.H.)
24. Lift cylinder (L.H.)
25. Slack adjuster (front)
26. Brake accumulator (for front)
27. Accumulator charge valve
28. PPC accumulator
29. Brake accumulator (for rear)
30. Brake emergency release valve
31. Breather
Outline
• The hydraulic system consists of the work equipment circuit and steering circuit. The work equipment
circuit controls the operation of the bucket and attachment.
• The oil in hydraulic tank (11) is sent to control valve (3) by work equipment pump (10). While the spools of
control valve (3) for the bucket and boom are in the hold position, the oil flows through the drain circuit of
control valve (3) and is filtrated by the filter in hydraulic tank (11) and returned to the tank.
• When the work equipment control lever is operated, the work equipment controller sends a command
current to EPC valve.
• EPC valve operates each spool of control valve (3) hydraulically in accordance with the command current.
• The oil flows from control valve (3) to lift cylinders (1) and (24) or bucket cylinder (2) to move the boom or
bucket.
• The maximum pressure in the hydraulic circuit is controlled with the relief valve in control valve (3). The
bucket cylinder circuit is equipped with a safety valve (with suction valve) to protect itself.
• Hydraulic tank (11) is of pressurized and sealed type, and equipped with an oil filler cap/breather having a
relief valve, which pressurizes the tank, prevents generation of negative pressure in the tank, and
prevents cavitation in the pump. Air is taken in through the breather (31).
• When the machine cannot be steered normally during travel because of an engine stall, steering pump
trouble, oil leakage from the piping, etc., electric emergency steering motor (18) is operated to drive
emergency steering pump (19) and enables steering (if equipped).
• Fan motor (14) installed to the radiator is driven with variable hydraulic pressure by cooling fan/ brake
pump (9).
WA470-7 10-181
10 Structure and function
Work equipment control
a The figure shows the machine with the auxiliary control lever.
10-182 WA470-7
10 Structure and function
Hydraulic tank
WA470-7 10-183
10 Structure and function
Hydraulic tank
4. Drain plug
5. Strainer
6. Filter element
7. Bypass valve
8. Suction strainer
9. Sight gauge
Specifications (WA470-PM30-030-K-00-A)
1. Bottom plate
2. Gasket
Prevention of pressure rise in tank
• While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and
the temperature in the hydraulic tank rise according to the operation of the hydraulic cylinders.
If the pressure in the tank exceeds the set pressure, bottom plate (1) is pushed up to release the pressure
in the tank and prevent pressure rise.
(Set pressure of air bleeding valve: 75 ± 15 kPa {0.76 ± 0.15 kg/cm 2})
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10 Structure and function
Hydraulic tank
Breather (WA500-PM38-041-K-00-A)
1. Body
2. Filter element
3. Poppet
4. Sleeve
Function (WA470-PM38-042-K-00-A)
• Prevention of negative pressure in tank
Since the tank is pressurized and sealed, the oil level in it decreases and negative pressure is generated
in it. At this time, poppet (3) is opened by the differential pressure from the ambient pressure. As a result,
the ambient pressure is let into the tank and generation of negative pressure is prevented.
(Set pressure of air bleeding valve: 0 – 2.9 kPa {0 – 0.03 kg/cm2})
• Prevention of pressure rise in tank
If the circuit pressure increases above the specified pressure because of the oil level change caused by
the hydraulic cylinder and temperature rise during operation, sleeve (4) operates to release the pressure
in the hydraulic tank.
(Set pressure of air bleeding valve: 137 ± 20 kPa {1.4 ± 0.2 kg/cm2})
WA470-7 10-185
10 Structure and function
Double type gear pump
• The double type gear pump consists of the power train charge pump and the power train lubrication pump.
• It is installed to the PTO shaft of the torque converter and driven by the PTO shaft to supply oil pressure to
the torque converter and transmission circuits.
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10 Structure and function
Work equipment pump
WA470-7 10-187
10 Structure and function
Work equipment pump
10-188 WA470-7
10 Structure and function
Work equipment pump
1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. PC valve
Structure
• Cylinder block (7) is supported to shaft (1) by spline (12).
• Shaft (1) is supported by each bearing (13) at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) rocks on cylindrical surface (B) of cradle (2) fixed to the case. High-pressure oil is supplied
between them to form a static pressure bearing.
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
WA470-7 10-189
10 Structure and function
Work equipment pump
• Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil.
• The oil pressure is balanced properly on the sealing surface of cylinder block (7) and valve plate (8).
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Specifications (WA470-C200-030-K-00-A)
Model HPV140
Type Variable displacement swash plate type piston pump
Theoretical delivery (cm3/rev) 120 ± 1
Rated delivery pressure: (MPa {kg/
34.3 {350}
cm2})
Rated speed (rpm) (*1) 2,282
*1: It shows the value when engine speed is at rated speed of 2,000 rpm.
Function (WA500-C200-042-K-00-A)
• This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic pressure
and discharges pressurized oil according to the load.
• It is possible to change the discharge by changing the swash plate angle.
Operation (WA470-C200-044-K-00-A)
Operation of pump
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane
(A) works as a cam for shoe (5).
• Piston (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder
block (7).
• Oil in amount of (F) minus (E) is sucked in and discharged from each piston (6).
10-190 WA470-7
10 Structure and function
Work equipment pump
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (F) increases.
• When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (7) is zero.
• Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however,
the swash plate angle does not become 0 deg.)
• The pump discharge is in proportion to swash plate angle (a).
Control of discharge
WA470-7 10-191
10 Structure and function
Work equipment pump
• When the swash plate angle (a) increases, the difference between volumes (E) and (F) increases and also
pump discharge (Q) increases.
• Swash plate angle (a) is changed by servo piston (10).
• Servo piston (10) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
• The linear reciprocating movement of servo piston (10) is transmitted to rocker cam (4) through slider (14).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• The area of servo piston (10) for receiving the pressure are not identical on the left side and right side.
Main pump discharge pressure (self pressure) (PP) is always brought to the pressure chamber of the
small diameter piston side.
• Output pressure (PEN) of LS valve is supplied to the chamber receiving the pressure at the large diameter
piston end.
• The movement of servo piston (10) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter side (PEN) and by the ratio of the area receiving the pressure
between small diameter piston and large diameter piston.
LS valve (WA470-C2J0-041-K-00-A)
10-192 WA470-7
10 Structure and function
Work equipment pump
Function (WA470-C2J0-042-K-00-A)
• The LS (load sensing) valve detects the load of the actuator and controls the pump discharge.
• The LS valve controls pump discharge (Q) according to differential pressure (dPLS) [ = (PP - PLS)] (called
LS differential pressure) between pump discharge pressure (PP) and control valve outlet port pressure
(PLS).
• The LS valve receives main pump pressure (PP) and pressure (PLS) (called the LS pressure) coming
from the control valve output.
WA470-7 10-193
10 Structure and function
Work equipment pump
Operation (WA500-C2J0-044-K-00-A)
• The LS valve is a 3-way selector valve, and LS pressure (PLS) on the inlet of the control valve is
transmitted to spring chamber (B), and pump discharge pressure (PP) is transmitted to port (H) of sleeve
(8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge
pressure (PP) determine the position of spool (6).
• Before the engine is started, servo piston (12) is pushed to the left. (See the figure below)
• When the control lever is in the NEUTRAL position when the engine is started, LS pressure (PLS) is set to
0 MPa {0 kg/cm2}. (It is connected to the drain circuit through the control valve spool)
• Spool (6) is pushed to the right, and port (C) and port (D) are connected.
• Shuttle valve output pressure (PPH) is transmitted to the large end of the piston through port (K).
• Pump pressure (PP) is transmitted to port (J) on small end side.
• According to the area difference of servo piston (12), the servo piston is moved in the direction which
makes the swash plate angle minimum.
10-194 WA470-7
10 Structure and function
Work equipment pump
• When the difference between pump discharge pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) becomes smaller [for example, when the area of opening of the control valve
becomes larger and pump discharge pressure (PP) drops], spool (6) is pushed to the left by the combined
force of LS pressure (PLS) and the force of spring (4).
• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve is connected to the drain port, the pressure between circuits (D) and (K) becomes
drain pressure (PT). (The operation of the PC valve is described later.)
WA470-7 10-195
10 Structure and function
Work equipment pump
• The pressure at the large end of servo piston (12) becomes drain pressure (PT) and pump pressure (PP)
is constantly transmitted to port (J) at the small end. Accordingly, servo piston (12) is pushed to the left
and moves the swash plate in the direction to increase the discharge.
• When LS differential pressure (dPLS) becomes larger (for example, when the area of opening of the
control valve becomes smaller and pump pressure (PP) rises), pump pressure (PP) pushes spool (6) to
the right.
• When spool (6) moves, shuttle valve output pressure (PPH) is transmitted to port (D) through port (C), and
then to the large end of the piston through port (K).
• Main pump pressure (PP) is transmitted to port (J) of the small end of the piston, but servo piston (12) is
pushed to the right because of the difference in area between the large and the small ends of servo piston
(12). As a result, the swash plate angle is decreased.
10-196 WA470-7
10 Structure and function
Work equipment pump
• The symbols (A1), (A0) and (PEN) respectively represent the area receiving the pressure at the large end
of the piston, the area receiving the pressure at the small end and the pressure transmitted to the large
diameter end of the piston.
• When main pump pressure (PP) of the LS valve is balanced with the combined force of LS pressure (PLS)
and spring (4) and (A0) x (PP) = (A1) x (PEN), servo piston (12) stops at the current position.
• The pump swash plate is held at an intermediate position. [The swash plate stops at a position where the
opening between ports (D) and (E) of spool (6) and that between ports (C) and (D) are approximately
equal]
• The relation between the area receiving the pressure at both ends of servo piston (12) is (A0):(A1) = 3:5,
so the pressure applied to both ends of the piston when it is balanced becomes (PP):(PEN) C 5 : 3.
• The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is
adjusted so that it is determined when (PP) - (PLS) = 1.4 MPa {14 kg/cm 2}.
WA470-7 10-197
10 Structure and function
Work equipment pump
PC valve (WA470-C2K0-041-K-00-A)
Function (WA470-C2K0-042-K-00-A)
• The PC valve limits the oil flow to a certain level (depends on the discharge pressure) even if the stroke of
the control valve is increased extremely when pump discharge pressure (PP) is high.
• If the pump discharge pressure increases due to increased load during operation, this valve decreases the
pump discharge.
• If the pump discharge pressure decreases, this valve increases the pump discharge.
• The relation between the pump discharge pressure (PP) and pump discharge (Q) is as shown in the
following figure, as a parameter for each current (X) value applied to the PC-EPC valve solenoid.
• The controller continues counting the actual engine speed.
• During low speed, command current (X) flows from the controller to PC-EPC valve solenoid according to
the engine speed to reduce the pump discharge.
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10 Structure and function
Work equipment pump
Operation (WA470-C2K0-044-K-00-A)
When actuator load is small and pump discharge pressure (PP) is low
WA470-7 10-199
10 Structure and function
Work equipment pump
• Depending on the position where spool stops, the pressure output from the PC valve [port (C) pressure]
varies.
• The amperage of the command current (X) depends on the type of work (lever operation), working mode
selection, engine speed setting, and the actual engine speed.
Action of spring
• The spring force of spring (4) in the PC valve depends on the position of the swash plate.
• When servo piston (9) compresses or decompresses spring (4), the spring force varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
• The spring force of spring (4) is also varied by the PC-EPC valve solenoid command current (X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Pump pressure (PP) is transmitted to the small diameter end of servo piston (9), port (A), and port (B).
• When pressures (PP) is low, spool (3) is at the left.
• Port (C) and port (D) are connected, and the pressure entering the LS valve will be drain pressure (PT).
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter side of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
• The pump discharge goes to increase.
• The movement of servo piston (9) lets spring (4) to expand, and the spring force decreases.
• When the spring force decreases, spool (3) moves to the right. Ports (C) and (D) are blocked, while pump
discharge pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.
10-200 WA470-7
10 Structure and function
Work equipment pump
• Stop position of servo piston (9) (= pump discharge) is determined by a position where the press force
generated by pressure (PP) on spool (3) and the thrust by PC-EPC valve solenoid and the force of spring
(4) are balanced.
• When the load is large and the pump discharge pressure (PP) is high, the thrust moving spool (3) to the
right increases, and spool (3) comes to a position as shown above.
• The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP), because a
part of the pressure from port (B) is transmitted to port (D) through the LS valve and port (C), as shown
above.
• When ports (E) and (G) of the LS valve are connected, the pressure is transmitted from port (J) to the
large diameter end of servo piston (9), and servo piston (9) stops moving.
• When pump pressure (PP) increases more and spool (3) moves further to the right, pump pressure (PP)
flows to port (C) to minimize the pump discharge.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed, and push back spool (3).
• When spool (3) moves to the left, the openings of ports (C) and (D) widen.
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
• At this time, servo piston (9) stops at a position further to the right than the position when pump pressure
(PP) is low.
• The relationship between pump pressure (PP) and pump average discharge (Q) becomes as shown in the
following figure.
WA470-7 10-201
10 Structure and function
Work equipment pump
• If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between
pump pressure (PP) and pump discharge (Q) is shifted parallel in proportion to the thrust of PC-EPC valve
solenoid.
• The thrust of PC-EPC valve solenoid (1) is added to the rightward thrust caused by the pump pressure
applied to spool (3), so the relationship between pump pressure (PP) and pump discharge (Q) moves from
(A) to (B) as the command current (X) is increased.
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10 Structure and function
Work equipment pump
C: To PC valve
P: From pilot lamp
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
Function (WA500-C2N0-042-K-00-A)
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
WA470-7 10-203
10 Structure and function
Work equipment pump
• When signal current (i) from the controller is received, an EPC output pressure proportional to the
amperage of current is generated and output to the PC valve.
Operation (WA500-C2N0-044-K-00-A)
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10 Structure and function
Work equipment pump
WA470-7 10-205
10 Structure and function
Work equipment pump
10-206 WA470-7
10 Structure and function
Work equipment pump
WA470-7 10-207
10 Structure and function
Control valve
a In this section, the 4-spool valve (with ECSS control valve) is described.
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10 Structure and function
Control valve
WA470-7 10-209
10 Structure and function
Control valve
10-210 WA470-7
10 Structure and function
Control valve
WA470-7 10-211
10 Structure and function
Control valve
10-212 WA470-7
10 Structure and function
Control valve
1. Unload valve
Bucket valve
2. EPC valve (dump)
3. Load check valve (tilt)
4. Pressure compensation valve (dump)
5. EPC valve (tilt)
6. Suction safety valve (dump)
7. Bucket spool
8. Suction safety valve (tilt)
WA470-7 10-213
10 Structure and function
Control valve
Boom valve
1. EPC valve (lower and float)
2. Load check valve (raise)
3. LS shuttle valve
4. Pressure compensation valve (lower)
5. EPC valve (raise)
6. Suction safety valve (lower and float)
7. Suction safety valve (lower and float)
8. Boom spool
10-214 WA470-7
10 Structure and function
Control valve
ECSS valve
10. ECSS spool
11. EPC valve (ECSS ON - OFF)
12. Accumulator charge valve
Attachment valve
1. EPC valve
2. Load check valve
3. LS shuttle valve
WA470-7 10-215
10 Structure and function
Control valve
9. Unload valve
10. Main relief valve
11. LS bypass valve
10-216 WA470-7
10 Structure and function
CLSS
CLSS (ALL-PNJ1-001-K-00-A)
Features
CLSS is an abbreviation for Closed center Load Sensing System, which has the following features.
• Fine control not influenced by load
• Control performance that allows digging even under fine control operation condition
• Ease of combined operation ensured by the flow dividing performance that is determined by the opening
areas of spools during combined operations
• Energy saving by variable discharge pump control
Configuration
• CLSS consists of variable capacity piston pump, control valves, and respective actuators.
• The variable capacity piston pump consists of a pump body, LS valve, and PC valve.
Basic principle
WA470-7 10-217
10 Structure and function
CLSS
• The pump swash plate shifts toward the maximum angle position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve.
• The pump swash plate shifts toward the minimum angle position if LS differential pressure is higher than
the set pressure.
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10 Structure and function
CLSS
LS differential pressure (d
d PLS) and pump swash plate angle
WA470-7 10-219
10 Structure and function
CLSS
• A valve to balance the load (pressure compensation valve) is installed on the lift cylinder head outlet side
of the control valve.
• When actuators are operated in combined operations, the pressure difference (dP) between the upstream
(inlet port) and downstream (outlet port) of the spool of each valve is kept the same among them,
regardless the level of the load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
• If the pressurized oil flows into the lift cylinder head too much because of the hydraulic drift of the boom
and combined operation of the bucket, the bucket does not move. This is prevented by the above control.
10-220 WA470-7
10 Structure and function
Hydraulic circuit diagram and names of valves
1. Bucket valve
2. Boom valve
3. ECSS valve
4. Attachment valve
5. Bucket spool
6. Boom spool
7. ECSS spool
8. Attachment spool
WA470-7 10-221
10 Structure and function
Hydraulic circuit diagram and names of valves
a: Orifice
b: Port
c: Port
P: Pump circuit
PLS: LS circuit
T: Tank circuit
1. Spring
10-222 WA470-7
10 Structure and function
Hydraulic circuit diagram and names of valves
2. Valve
Function
• Drains an oil discharge for the portion of the minimum pump swash plate angle while all control valves are
in the holding.
• The pump pressure will correspond to a set load of spring (5) inside the valve (this pressure will be P1).
• Since LS pressure is drained from the LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}
Operation
WA470-7 10-223
10 Structure and function
Hydraulic circuit diagram and names of valves
1. Main pump
Pressure compensation valve
2. Load check valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function
• High load pressure is generated during independent operation of the boom and combined operation with
the bucket.
• When the load pressure of the boom is higher than the pump pressure, this valve functions as a load
check valve to prevent reverse oil flow in the circuit.
Operation
• Actuator circuit pressure (B) increases higher than pump discharge pressure (PPS) and LS pressure
(PLS).
• Shuttle valve (3) of the pressure compensation valve moves to the right.
10-224 WA470-7
10 Structure and function
Hydraulic circuit diagram and names of valves
Function
• When the flow rate of the boom starts to increase because the load pressure of the boom becomes lower
than that of the bucket during combined operation, this valve compensates the pressure on the boom side.
• On the bucket side, the load pressure is higher and the flow rate starts to decrease.
Operation
• When the load pressure on the boom side increases during combined operation, the flow to the actuator
circuit (B) starts to increase.
• Since the LS pressure (PLS) on the bucket side increases, it pushes shuttle valve (3) of the pressure
compensation valve on the boom side to the left.
• The pressurized oil flows through the internal passage of piston (4) to spring chamber (C).
• Piston (4) and valve (2) are pushed to the left to close the outlet side of pump circuit (PPS).
• Outlet pressure (A) (spool meter-in downstream pressure) becomes equal to the output pressure of the
bucket.
• Pump pressure (PPS) (spool meter-in upstream pressure) becomes the same in all the actuators.
• Pump pressure (PPS) and outlet pressure (A) become the same in all the operated spools.
• The pump discharge flow is divided in proportion to the opening area of each spool.
WA470-7 10-225
10 Structure and function
Hydraulic circuit diagram and names of valves
1. Hydraulic pump
2. Load check valve
3. Shuttle valve
4. Piston
Function (WA500-C7C0-042-P-00-A)
• Shuttle valve (3) is pushed to the right by the port (B) pressure to disconnect the port (B) from port (D).
• The holding pressure of port (B) is transmitted to spring chamber (C) to push piston (4) to the left so that
piston (4) and load check valve (2) do not separate from each other.
10-226 WA470-7
10 Structure and function
Hydraulic circuit diagram and names of valves
• The flow division ratio varies with the surface area ratio of portions (A1) and (A2) of the pressure
compensation valve. Surface area ratio = (A2)/(A1)
• When the surface area ratio is 1: The spool meter-in downstream pressure is equal to the maximum load
pressure and oil flows in accordance with the opening area ratio of spool meter-in.
• When the surface area ratio is 1 or more: The spool meter-in downstream pressure is more than the
maximum load pressure and oil flows less than the opening area ratio of spool meter-in into the lower
pressure side.
• When the surface area ratio is 1 or less: The spool meter-in downstream pressure is less than the
maximum load pressure and oil flows more than the opening area ratio of spool meter-in into the lower
pressure side.
WA470-7 10-227
10 Structure and function
Hydraulic circuit diagram and names of valves
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. Load check valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function (WA500-L1P0-042-K-00-A)
• LS pressure (PLS) is the actuator load pressure on the outlet side of the control valve.
• The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is
transmitted through main spool (2) to LS shuttle valve (7).
• The LS pressure is connected through valve (5) to port (B) of the actuator, and then it ≒ the actuator load
pressure.
• Inlet hole (a) in main spool (2) is small in diameter and has a throttling function.
Operation (WA500-L1P0-044-K-00-A)
• When main spool (2) is operated, the discharged oil from pump flows into actuator circuit (B).
• Pump discharge pressure (PPS) is transmitted through inlet hole (a) of main spool (2) to LS circuit (PLS).
• Pump discharge pressure (PPS) increases to the necessary pressure for actuator circuit (B).
10-228 WA470-7
10 Structure and function
Hydraulic circuit diagram and names of valves
• Check valve (5) in main spool (2) opens and the high pressure oil of LS circuit (PLS) flows into actuator
circuit (B).
• The pressure in LS circuit (PLS) becomes almost the same as that in actuator circuit (B).
LS bypass plug (WA470-PNSH-041-K-00-A)
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function (WA500-PQH2-042-K-00-A)
• This valve releases the remaining pressure in LS pressure circuit (6) through orifices (a) and (b).
• This valve decreases the rising speed of the LS pressure to prevent a sudden change of the oil pressure.
• Since the oil flows through LS valve (5), pressure loss is made by the circuit resistance between throttle
(c) of main spool (2) and LS shuttle valve (4).
• The effective LS differential pressure decreases to improve the dynamic stability of the actuator.
WA470-7 10-229
10 Structure and function
Hydraulic circuit diagram and names of valves
1. Spool
2. Solenoid valve
3. Plug
4. Nut
5. Check valve
Function (WA500-L320-042-K-00-A)
• The controller automatically turns ON/OFF the accumulator charged with the high-pressure gas according
to the travel condition of the machine.
• This valve gives elasticity to the vertical movement of the work equipment to restrict the machine body
from rocking, improve the operator comfort, and prevent the load from spilling during high-speed travel.
Operation (WA500-L320-044-K-00-A)
• When the travel speed exceeds 5 km/h, the signal enters solenoid valve (2) and the pressure is
transmitted to (a).
• Spool (1) moves to the left.
• When spool (1) moves, the passage of (PR) → accumulator (ACC) closes and the passage of (A2) →
accumulator (ACC), (B2) → (T) opens, and ECSS is turned ON.
• When the travel speed is 4 km/h or below, no signal enters solenoid valve (2) and spool (1) is kept in
neutral position. At this time, the passage of (PR) → accumulator (ACC) opens and accumulator (ACC) is
charged.
10-230 WA470-7
10 Structure and function
Hydraulic circuit diagram and names of valves
• When accumulator (ACC) is charged up to the set pressure, check valve (5) closes and the pressure in
the accumulator (ACC) does not increase any more.
WA470-7 10-231
10 Structure and function
Accumulator charge valve
10-232 WA470-7
10 Structure and function
Accumulator charge valve
WA470-7 10-233
10 Structure and function
Accumulator charge valve
Function
• The discharge pressure (P) of the hydraulic pump is reduced and the pressurized oil is supplied to the
accumulator for ECSS.
Operation
• Spring (3) presses poppet (2) against the seat and the line between ports (P1) and (T) is closed.
• Check valve (6) is pushed to the left and the line between ports (P1) and (PR) is closed.
• Check valve (6) is moved to the right by the pressure of (P1) and the line between (P1) and (PR) is
opened. When (P1) < (PR), spring (7) pushes check valve (6) to the left and the line between ports (P1)
and (PR) is closed.
10-234 WA470-7
10 Structure and function
Accumulator charge valve
Operation
• When the pressure increases to the set pressure or above, poppet (3) opens and the pressurized oil flows
from port (P1) through hole (a) in spool (5) and the opening of poppet (2) to tank port (T). As a result,
pressure P2 is kept constant.
• When pressure P1 is larger than pressure P2, spool (5) moves to the left and closes the opening of the P
o (P1) part. When pressure P1 becomes smaller than pressure P2, the opening of the P o (P1) part
opens. The pressure (P) is reduced to equalize pressure P2 and pressure P1 when this movement is
repeated.
WA470-7 10-235
10 Structure and function
Work equipment lock solenoid valve
• This valve is installed between the charge valve and work equipment EPC valve. Upon receiving the
operation signal from the work equipment controller, the solenoid is "energized" to block the oil to the work
equipment EPC valve and disables the operation of the work equipment.
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10 Structure and function
Accumulator (for PPC circuit)
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Specification (WA380-PL40-030-K-00-A)
Function (WA380-PL40-042-K-00-A)
• This accumulator is installed between the charge valve and work equipment PPC valve. Even if the
engine is stopped while the work equipment is raised, pilot oil pressure can be supplied to the work
equipment control valve with the pressure of the compressed nitrogen gas in the accumulator to lower the
work equipment by its own weight.
WA470-7 10-237
10 Structure and function
Accumulator (for ECSS)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Specifications (WA470-L370-030-K-00-A)
Function (WA380-L370-042-K-00-A)
• This accumulator is installed in the lift cylinder bottom circuit. The space between cylinder (3) and free
piston (4) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulsation generated on the lift
cylinder bottom side to improve the travel performance and workability during travel by utilizing its
compressibility.
10-238 WA470-7
10 Structure and function
Work equipment linkage
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Boom
6. Bucket link
WA470-7 10-239
10 Structure and function
Bucket
Bucket (WA470-LB00-041-K-00-A)
1. Bucket
2. Wear plate
3. Bolt-on cutting edge
4. Bucket tooth (if equipped)
10-240 WA470-7
10 Structure and function
Bucket positioner and boom positioner
1. Bell crank
2. Boom
3. Bucket potentiometer
4. Bucket potentiometer lever
5. Boom potentiometer
6. Front frame
7. Boom potentiometer lever
WA470-7 10-241
10 Structure and function
ROPS cab
10-242 WA470-7
10 Structure and function
Engine control system
WA470-7 10-243
10 Structure and function
Engine control system
Function
• The neutral safety circuit is employed to secure safety when the engine is started.
• The engine does not start while the directional lever is not in the "N" position.
• When you cannot stop the engine due to stuck starting switch, engine shutdown secondary switch is
usable for stopping the engine.
Operation
10-244 WA470-7
10 Structure and function
Preheating system
Operation (WA470-AM40-044-K-00-A)
• When the starting switch is turned to the "ON" position, the engine controller starts.
• When the intake air temperature is -5°C or below, the engine controller drives the preheater relay just after
the starting switch is turned to the "ON" position, and then the electric heater relay operates and the
electric heater start preheating the engine.
• The operating time of the preheater is shown below.
WA470-7 10-245
10 Structure and function
Preheating system
Operation (WA380-AM40-044-K-01-A)
• If the starting switch is turned to the "Manual preheating" position, the electric heater relay operates and
the electric heater starts preheating.
10-246 WA470-7
10 Structure and function
Engine power mode selector circuit
• The engine output can be maximized by turning the power mode selector switch to the "P mode" position.
The fuel consumption during work can be reduced by setting the power mode selector switch to the "E
mode".
• The switch signal is input to the work equipment controller. The work equipment controller sends the
signal to the transmission controller, which selects a proper gear speed and travel speed matched to the
power mode in the auto-shift mode.
Operation (WA380-AP11-044-K-00-A)
• When the power mode selector switch is turned to the "P mode" position, the switch signal is input to the
work equipment controller and the CAN signal is sent to the transmission controller.
• The transmission controller determines the final engine mode and sends the CAN signal to the engine
controller, and the engine torque performance curve changes to the "P-mode".
• When the engine mode is set to the "P mode" with the one-touch power maximizing function, the
transmission controller also sends the CAN signal to the engine controller, and the engine torque
performance curve changes to the "P-mode".
• The transmission controller sends the engine output mode pilot lamp lighting signal to the machine
monitor with the CAN signal .
WA470-7 10-247
10 Structure and function
Engine output limit function
• If the engine controller recognizes a failure, it limits the engine torque or engine speed to protect the
engine.
• The engine torque performance when the torque is limited is shown in the following figure.
10-248 WA470-7
10 Structure and function
Automatic warm-up function
• When the engine is started in a cold district, the low idle speed of the engine is increased automatically to
warm up the engine.
• If the coolant temperature is 30°C or below when the engine is started, the low idle speed increases to
1,020 rpm. The condition for the low idle speed to increase is determined according to the coolant
temperature as shown in the following figure.
• If the coolant temperature reaches 60°C or higher or the accelerator pedal position is kept at 70% or
above for 3 seconds or longer during the warm-up operation, the automatic warm-up function is canceled
and the engine speed returns to 800 rpm.
WA470-7 10-249
10 Structure and function
Parking brake control system
• When parking brake switch (2) is turned "ON" (operating), the current from the battery relay flows through
parking brake switch (2) to the coil of parking brake relay (1) and the contacts close.
• If the contacts of parking brake relay (1) are closed, the current from the battery relay continues to flow
into the coil, and the relay contacts are held until the current from the battery relay is cut out.
• No current flows in parking brake solenoid valve (3), and the parking brake keeps applied.
• Transmission controller (4) recognizes the operation signal of parking brake switch (2) and keeps the
transmission in neutral while the parking brake is in operation to prevent dragging of the parking brake.
• If parking brake switch (2) is turned "OFF" (release), the current from the battery relay flows through
parking brake relay (1), parking brake switch (2), and auto idle stop parking brake relay (5) to parking
brake solenoid valve (3), and then release the parking brake.
When parking brake switch is turned "OFF" (releasing) before starting switch is turned "ON"
10-250 WA470-7
10 Structure and function
Parking brake control system
• When parking brake switch (2) is turned "OFF" (release), no current flows in parking brake relay (1) and
the relay contacts are open.
• Even if starting switch is turned "ON", no current flows to parking brake solenoid valve (3). Accordingly, the
parking brake is not released automatically.
• If parking brake switch (2) is turned "OFF" (release) while the starting switch is turned "ON", the current
from the battery relay flows through parking brake relay (1), parking brake switch (2), and auto idle stop
parking brake relay (5) to parking brake solenoid valve (3), thus the parking brake is kept released.
• When the auto idle stop operates, transmission controller (4) outputs a current to auto idle stop parking
brake relay (5).
• The current flows in the coil of auto idle stop parking brake relay (5) and the contacts open.
• No current flows in parking brake solenoid valve (3), and the parking brake is applied.
• When the auto-idle stop operates, the parking brake also operates automatically and keeps operating
during restarting operation.
WA470-7 10-251
10 Structure and function
System operating lamp function
10-252 WA470-7
10 Structure and function
System operating lamp function
a When you want to cut off the battery circuit for maintenance but the system operating lamp keeps on
lighting up, turn the starting switch to the "ON" position once, then turn it to the "OFF" position. The lamp
will go out in two minutes maximum.
After the system operating lamp goes out, turn the battery disconnect switch to the OFF position
immediately.
WA470-7 10-253
10 Structure and function
Battery disconnect switch function
O: OFF
I: ON
Function (WA380-AW1P-042-K-00-A)
• Usually, the battery disconnect switch is used instead of disconnecting the cable from the negative
terminal of the battery in the following cases.
1. When storing the machine for a long period (more than one month)
2. When servicing or repairing the electrical system
3. When performing electric welding
• When the battery disconnect switch is turned OFF (the contact is opened), all the continuous power
supplies for the components, including the starting switch B terminal and controllers, are all cut out, and
the condition is the same as the condition when the battery is not connected. Accordingly, all the electric
system of the machine is disabled.
10-254 WA470-7
10 Structure and function
Battery disconnect switch function
• If the battery disconnect switch is turned OFF while the alternator is generating power, the generated
current has nowhere to go, leading to overvoltage in the electrical system of the machine, which may
cause serious damage to the electrical system, including the electric devices and controllers.
• If the battery disconnect switch is turned OFF for a long period, the machine monitor and the clock of the
radio may be initialized. In this case, re-setting is required.
WA470-7 10-255
10 Structure and function
Transmission controller system
a The display of the travel speed explained in this section is for the tires of size 26.5-25, unless otherwise
specified.
Transmission controller system diagram (WA470-CN20-051-K-00-A)
10-256 WA470-7
10 Structure and function
Transmission controller system
WA470-7 10-257
10 Structure and function
Transmission controller system
1. Engine
2. Torque converter
3. Transmission
4. Axle
5. Transmission controller
6. Combination switch
7. Accelerator pedal
8. Transmission ECMV
9. Engine speed sensor
10. Transmission input speed sensor
11. Transmission output speed sensor
10-258 WA470-7
10 Structure and function
Transmission controller system
Input/output signal
a. Directional signals
b. Shift range signal
c. Accelerator signal
d. Transmission output speed signal
e. ECMV operation signal
f. Fill switch signal
g. Transmission input speed signal
h. Engine speed signal
• The modulation control system controls the clutch pressure so that the transmission is shifted properly to
all the gear speeds (including the lockup clutch) and less shocks are generated at gear shifting
(engagement of the clutch) according to the engine speed, transmission oil temperature, transmission
input and output speeds, and gear shift pattern.
• The clutch pressure is so controlled that the difference between the input and output speeds will follow the
target value corresponding to the engine speed and accelerator pedal position to prevent sharp
engagement.
• After the clutch is disengaged, the disengagement pressure is kept low to prevent loss of torque until
engagement of the clutch starts.
• If abnormal gear shift time lag occurs, the learning function corrects the modulation automatically.
WA470-7 10-259
10 Structure and function
Transmission controller system
• There are two modes of "H" and "L" in the auto-shift mode, which are selected as shown in the following
table according to the condition of the transmission mode selector switch and power mode selector switch.
Power mode Transmission shift mode selector switch
selector switch H L MANUAL
P mode Auto-shift H mode Auto-shift L mode Manual shift mode
E mode Auto-shift L mode Auto-shift L mode Manual shift mode
• In the auto-shift mode, the upshift/downshift operations are controlled, corresponding to the directional
lever, gear shift lever, travel speed, accelerator pedal position, and engine speed.
10-260 WA470-7
10 Structure and function
Transmission controller system
WA470-7 10-261
10 Structure and function
Transmission controller system
10-262 WA470-7
10 Structure and function
Transmission controller system
C 1,181 {16}
WA470-7 10-263
10 Structure and function
Transmission controller system
10-264 WA470-7
10 Structure and function
Transmission controller system
WA470-7 10-265
10 Structure and function
Transmission controller system
• The hydraulic cooling fan is employed and the swash plate angle of the hydraulic pump is controlled to
reduce the horsepower loss and noise at low temperature.
• The transmission controller receives the engine speed and coolant temperature received by the engine
controller via the network. The transmission controller also directly receives the information on the
hydraulic oil temperature and torque converter oil temperature.
• The transmission controller sends the signal current to the swash plate angle control EPC valve of the
cooling fan pump on the basis of the received information and sets the fan speed corresponding to each
temperature and engine speed by controlling the swash plate angle.
10-266 WA470-7
10 Structure and function
Transmission controller system
1. Radiator
2. Cooling fan motor
2a. Cooling fan reverse rotation solenoid valve
3. Cooling fan pump
3a. Swash plate angle control EPC valve
4. Cooling fan speed sensor
5. Accelerator pedal
6. Engine
7. Coolant temperature sensor
8. Engine speed sensor
9. Engine controller
10. Transmission controller
11. Hydraulic oil temperature sensor
12. Hydraulic tank
13. Torque converter oil temperature sensor
14. Torque converter
15. Monitor controller
16. Front brake accumulator pressure drop sensor switch
17. Rear brake accumulator pressure drop sensor switch
Input/output signal
a. Accelerator position signal
b. Coolant temperature signal
c. Engine speed signal
d. CAN signal
e. Cooling fan speed signal
WA470-7 10-267
10 Structure and function
Transmission controller system
*1: The target fan speed is decided by the highest temperature information among the coolant temperature,
hydraulic oil temperature, and torque converter oil temperature. However, when the coolant temperature is
low, the torque converter oil temperature is not used.
*2: In this range, the fan speed corresponds to the coolant temperature, hydraulic oil temperature, and torque
converter oil temperature.
*3: When the air conditioner is in operation, the minimum speed becomes 600 rpm.
10-268 WA470-7
10 Structure and function
Transmission controller system
• The ordinary fan control based on "Fan speed set by temperature" is performed.
WA470-7 10-269
10 Structure and function
Transmission controller system
10-270 WA470-7
10 Structure and function
Transmission controller system
2) Engine coolant temperature: Ignored. The value obtained from the remaining normal sensors are used.
However, if neither of the hydraulic oil temperature and torque converter oil temperature is recognized, the
engine coolant temperature is assumed to be 90 °C.
3) Hydraulic oil temperature: Ignored. The value obtained from the remaining normal sensors are used.
4) Torque converter oil temperature: Ignored. The value obtained from the remaining normal sensors are
used.
Transmission cut-off function (WA380-CP30-042-K-00-A)
• The transmission cut-off oil pressure sensor detects the brake pilot pressure when the right and left brake
pedals are depressed and the transmission is set in neutral.
• The transmission can be cut off at any position by saving the brake pilot pressure at the brake pedal
position where the transmission comes in neutral.
1. Contents of control
• If the transmission cut-off operating condition is met, the transmission is set in
neutral.
Outline • If the transmission cut-off cancellation condition is met, the cut-off is canceled
and the transmission gear is shifted by modulation.
<Operating condition in 1st or 2nd gear>
• The transmission cut-off pilot lamp is turned "ON" and the brake pilot pressure
Transmis- exceeds the cut-off-IN pressure.
sion cut- Operating <Operating condition in 3rd or 4th gear>
off control condition • The transmission cut-off pilot lamp is turned "ON" and the accelerator pedal
depression is larger than 30% and the brake pilot pressure exceeds the IN
pressure of the cut-off circuit.
Condition The cut-off is canceled when any of the following conditions is met.
for
cancella- • The transmission cut-off pilot lamp is turned "OFF".
tion • The brake pilot pressure is below the OUT pressure of the cut-off circuit.
Condition
possible to • The transmission cut-off pilot lamp is turned "ON".
be set
1) The brake pedal is depressed to a set position. (Setting is possible even if the
brake pedal is not depressed)
2) The transmission cut-off set switch is pressed.
3) The brake pilot pressure when the switch is pressed is recognized.
<In case of within settable range>
The brake pilot pressure when the switch is pressed is saved temporarily.
Setting <In case of out of settable range>
method The upper or lower limit of the brake pilot pressure in the settable range is saved
Setting of temporarily.
transmis- The setting completion buzzer (pip, pip) sounds.
sion cut-
off point 4) The transmission cut-off switch built-in pilot lamp flashes for 2.5 seconds.
5) The set value is saved. (Setting mode is finished)
a The set condition is maintained even after the starting switch is turned to the
"OFF" position.
1) Under the condition of setting method Step 4) (the pilot lamp built in the
transmission cut-off switch flashes for 2.5 seconds), press the transmission cut-off
set switch again.
Resetting 2) The pilot lamp stops flashing and the cut-off point is set to the brake pilot pressure
method in default. The setting cancel buzzer (peep) sounds.
3) The set (default) value is saved. (Setting mode is finished)
a The set condition is maintained even after the starting switch is turned to the
"OFF" position.
2. Outputting condition
WA470-7 10-271
10 Structure and function
Transmission controller system
Buzzer
Pilot lamp built-in command
Outputting condition transmission cut-off Cut-off point
(Communication
switch
output)
Controlled by
Transmission cut-off pilot lamp is turned "ON". Lights up None previously saved
value
Transmission cut-off pilot lamp is turned "ON" When set switch
and transmission cut-off set switch is turned is pressed,
"ON". Flashes Brake pilot pressure
setting
(For 2.5 seconds or when set switch is
For 2.5 seconds or until resetting (sensor is completion
until resetting) pressed is saved.
normal) buzzer sounds
Setting method Steps 2) to 5) (pip, pip).
None
Transmission cut-off pilot lamp lamp is turned (Error is Control is not made.
"ON" and transmission cut-off pressure sensor Keeps turned OFF displayed on Saved value is not
is abnormal. machine changed.
monitor)
None Controlled by
(Error is position where error
Transmission cut-off pilot lamp is turned "ON" Lights up occurred. Saved
displayed on
and transmission cut-off set switch is abnormal value is not
machine
monitor) changed.
When set switch
Transmission cut-off pilot lamp is turned "ON" is pressed,
and transmission cut-off set switch is turned Default value for
setting
"ON". Lights up brake pilot oil
cancelltion
pressure is saved.
Reset during 2.5 seconds buzzer sounds
(peep).
Transmission cut-off pilot lamp is turned "OFF" Goes out None Control is not made.
a While the transmission is cut off, "N" is displayed on the shift indicator of the machine monitor. (Travel
direction output signal "N")
a If the transmission is cut off after the kickdown switch is pressed to set the gear speed to the 1st, it is
reset to the 1st, regardless of the shift mode.
a When the lockup is in operation, the cut-off operates after the lockup is released.
3. Settable range of transmission cut-off point
Settable range
0.49 to 4.41 MPa {5 to 45 kg/cm2}
Note 1: When the cut-off point is set 0.49 MPa {5 kg/cm2} or less, it is actually set to 0.49 MPa {5 kg/cm2}.
Note 2: When the cut-off point is set 4.41 MPa {45 kg/cm2} or more, it is actually set to 4.41 MPa {45 kg/
cm2}. The default value is 1.47 MPa {15 kg/cm2}.
• Set a hysteresis of 0.20 MPa {2 kg/cm2} between cut-off-IN (neutralizing) pressure and cut-off-OUT
(restoration) pressure.
Example) When pressure sensor is set to a position of 0.98 MPa {10 kg/cm2}
Cut-off-IN pressure = 0.98 MPa {10 kg/cm2}
Cut-off-OUT pressure = 0.78 MPa {8 kg/cm2}
10-272 WA470-7
10 Structure and function
Transmission controller system
1. Transmission controller
2. Gear shift lever
3. Speed sensor
4. E.C.S.S. switch
5. 1st clutch ECMV
6. 2nd clutch ECMV
7. 3rd clutch ECMV
8. 4th clutch ECMV
9. E.C.S.S. solenoid valve
Input/output signal
a. Gear shift lever "1st" signal
b. Gear shift lever "2nd" signal
c. Gear shift lever "3rd" signal
d. Gear shift lever "4th" signal
e. Travel speed signal
f. Pulse GND
g. E.C.S.S. switch "ON" signal
h. 1st clutch ECMV operation signal
i. 2nd clutch ECMV operation signal
j. 3rd clutch ECMV operation signal
k. 4th clutch ECMV operation signal
l. ECMV GND
m. ECMV GND
n. E.C.S.S. operation signal
Function (WA380-L3B0-042-K-00-A)
• The ECSS gives elasticity to the vertical movement of the work equipment to restrict rocking of the
machine body, improve the operator comfort, prevents the load from spilling, and improves the working
efficiency during high-speed travel by using the buffering effect of the accumulator charged with high-
pressure gas and automatically controlling the relief pressure of the lift cylinder for the traveling condition.
Setting method
• The ECSS does not function unless “ECSS Operating Speed“ is set to "ADD" with the "Option selection
function" of the machine monitor.
a For the setting procedure, see Testing and adjusting, "Special functions of machine monitor".
WA470-7 10-273
10 Structure and function
Transmission controller system
Operation (WA500-L3B0-044-K-00-A)
• The operating condition of the ECSS is as per the following table.
Boom lever E.C.S.S. operation
ECSS switch Gear speed Travel speed [km/h]
condition (*1) signal
OFF All gear speeds 0 to Max. ON/OFF OFF
All gear speeds 0 to Max. OFF OFF
1st 0 to Max. ON/OFF OFF
ON
(*3) Max. 4 ON/OFF OFF
2nd to 4th
(*2) Min. 5 ON ON
*1. Boom lever condition ON: Boom lever stroke > -80%
• The switch to select the travel direction is installed on the side of the work equipment control lever
independently from the standard directional lever so that the operator can select the travel direction with
his/her right hand.
1. Selection of directional selector switch
• When only the directional lever is used, the directional lever input signal leads to recognition of
travel direction. Since the switch to select the travel direction is added, a selector switch is installed
to select the additional switch or the directional lever.
a The operation with the directional selector switch is selected only when the directional selector
switch actuation switch is turned ON. However, the directional lever (standard directional lever) is
given the priority for the operation.
• The condition for operating with the directional selector switch is that the standard directional lever
is in N (Neutral), the directional selector switch is in N (Neutral), and the directional selector switch
actuation switch is turned ON.
a When travel direction can be changed with the directional selector switch, the directional selector
pilot lamp of the machine monitor lights up in green.
a If the directional selector switch actuation switch is turned ON/OFF while either is not in N (Neutral),
the directional selector pilot lamp of the machine monitor lights up in yellow and the caution lamp
lights up.
• Even if the directional selector switch is effective, if the standard directional lever is set in a position
other than N (F or R), the travel direction is set according to the operation of the directional lever.
10-274 WA470-7
10 Structure and function
Transmission controller system
Since the directional operation is not selected normally, the directional selector pilot lamp of the
machine monitor lights up in yellow and the caution lamp lights up.
a If the alarm operates and the directional selector pilot lamp lights up in yellow, the alarm is not
turned OFF and the directional selector switch does not work until both of the standard directional
lever and the directional selector switch are set in N (Neutral).
• The above description is shown in the table below.
Right Monitoring
FNR operation
Mode Condition FNR recognition
enabled/ (Reference)
disabled
Directional lever: [F or N or R]
OFF Pilot lamp
Directional lever Directional selector switch: [N] Subject to directional
(dis- Goes out
(normal) Directional selector switch lever
abled) Buzzer stops
actuation switch: [OFF]
Directional lever: [N]
Directional selector Pilot lamp
Directional selector switch: [F ON
switch enable switch Subject to directional Lights up in
or N or R] (en-
(normal [directional selector switch green
Directional selector switch abled)
selector switch]) Buzzer stops
actuation switch: [ON]
Directional lever: [F or R]
Pilot lamp
OFF
Directional lever priority Directional selector switch: [F Subject to directional Lights up in
or N or R] (dis-
(emergency operation) lever yellow
Directional selector switch abled)
Buzzer stops
actuation switch: [ON]
Directional lever: [F or N or R]
Subject to directional Pilot lamp
Directional lever, Directional selector switch: [F OFF
lever Lights up in
directional switch error or R] (dis-
(Directional selector yellow
(wrong operation) Directional selector switch abled)
switch is ignored) Buzzer stops
actuation switch: [OFF]
Directional lever: [other than
N] Pilot lamp
OFF
<e> Selection error Directional selector switch: Subject to directional Lights up in
[other than N] (dis- yellow
(wrong operation) lever
abled)
Directional selector switch Buzzer stops
actuation switch: [OFFio
2. Interlock when engine is started (Prohibition of starting of engine)
When the directional selector switch actuation switch is in the ON position and the directional selector
switch is not in the N (Neutral) position, the transmission controller operates the neutral safety function
to cut the starting motor C terminal signal to prevent the machine from moving just after the engine is
started.
3. Setting of directional selector switch
The directional selector switch does not perform control, unless the option setting of the directional
selector switch is set effective by the option setting of the machine monitor. This switch cannot be
installed together with joystick steering.
a For the method of setting the option, see Testing and Adjusting, "Special functions of machine
monitor".
Auto idle stop function (WA380-AF87-042-K-00-A)
• When the operating condition is satisfied, the engine is stopped after a set period.
• After the engine is stopped, if the parking brake switch is in OFF position, the parking brake is applied.
• After the engine is stopped, if the work equipment lever lock is released, the work equipment lever lock is
operated.
• This function works when conditions 1 to 4 are satisfied at the same time.
a For the adjustment procedure of the set time, see Testing and Adjusting, "Special functions of machine
monitor".
WA470-7 10-275
10 Structure and function
Transmission controller system
Operating condition
Condition 1 Accelerator pedal is released
Condition 2 Directional lever is in neutral
Condition 3 Machine is stopped
Condition 4 KDPF is not in regeneration
Action for restarting engine
To restart the engine, turn the starting switch from the ON position to the START position.
Real-time monitoring function of transmission controller (WA380-CV3G-042-K-00-A)
The conditions of the input and output signals of the controller can be checked with the monitoring function of
the machine monitor.
a For the monitoring procedure, see Testing and adjusting, "Special functions of machine monitor".
Transmission controller self-diagnosis function (WA380-CN1G-042-K-00-A)
• The transmission controller constantly monitors the input and output conditions and performs self-
diagnosis of the system.
• If any failure is detected by the self-diagnosis, its information is sent to the machine monitor through the
network.
• If any failure occurs, it can be checked with the machine monitor / KOMTRAX.
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10 Structure and function
Work equipment control system
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10 Structure and function
Work equipment control system
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10 Structure and function
Work equipment control system
Function
• The work equipment control lever has a play of 5% of the lever travel in the neutral position. The work
equipment starts moving when the lever moves over the play.
• The work equipment speed for the lever travel can be changed by the setting of the controller.
• The boom has five changeable tables and the bucket has three.
a For the adjustment method and the features of each table, see Testing and adjusting "Changing boom
lever pattern" and "Changing bucket lever pattern".
Boom lever stroke vs. speed table
WA470-7 10-279
10 Structure and function
Work equipment control system
1. Transmission controller
2. Work equipment lock switch
3. Work equipment controller
4. Monitor controller
5. Machine monitor
6. Work equipment neutral lock valve
Function (WA380-PTLD-042-K-00-A)
• When the work equipment lock switch is operated, the controller turns OFF the output of the work
equipment EPC to stop the operation of the work equipment.
• When the ECSS switch is turned OFF, the work equipment neutral lock valve is turned ON. Then, the EPC
pilot source pressure is cut and the operation of the work equipment is stopped.
• When the lever is operated while the work equipment is locked even if the operator tries to unlock the work
equipment, the work equipment is not unlocked but kept locked for safety.
Work Operation Controller output Movement
Controller
equip- of ECSS of machine
ment Work equipment
control lock
lever indicator
condi- Work
Operator's ECSS equip-
tion switch
intention in Work ment
when signal
operation of work equip- EPC,
work Recogni- (Transmis- ment lock Hydraulic
equipment lock work
equip- zes sion
switch solenoid equip-
ment controller Switch Monitor
valve ment
lock input)
switch detent
is
oper-
ated
Cut (Work
ECSS ON equipment
switch = ON ON
In locking (no OFF
(24 V) OFF (No and ECSS
— In locking (Lights (Lights stop)
switch operation) output)
up) up)
ECSS SW OFF Only ECSS
= ON (OPEN) operates
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10 Structure and function
Work equipment control system
Function
• The work equipment controller detects the quantity of RAISE/LOWER and TILT/DUMP operations through
the signals of the work equipment control lever potentiometers, controls the operation of each EPC valve
with current, and operates the main spool with the EPC pressure to operate the work equipment.
WA470-7 10-281
10 Structure and function
Work equipment control system
• The work equipment control lever has detent notches and the system is adjusted so that the work
equipment operates at the maximum speed just before each detent.
• The range beyond the LOWER detent is the "Boom float" position, where the boom is moved by external
forces.
Function
• Since this machine employs the CLSS, it can operate the bucket and boom simultaneously. However, it
can prevent the boom from rising to improve the digging work efficiency when the bucket operation
frequency is large.
• This is realized by limiting the maximum boom rising speed for the bucket speed (Table below).
Function
• When the operator performs boom stop operation faster than a certain speed, the work equipment
controller operates the modulation to reduce the stopping shocks of the boom raise/lower operation.
• The operation of this stop modulation function can be changed by the setting of the controller.
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10 Structure and function
Work equipment control system
a For the changing method and precautions, see Testing and adjusting, "Boom stop modulation".
Case A: Modulation 0
When lever command flow > modulation command flow
• Output matched to lever command flow
Case B: Modulation 20
When lever command flow < modulation command flow
• Output matched to modulation command flow
a: Modulation 10 (when shipped)
b: Modulation starting position
Adjustment of lever detent position and work equipment starting current (WA380-PLT5-042-K-00-A)
Function
• The work equipment controller has the adjustment function of correcting dispersion.
• The controller saves the lever potentiometer voltage in the detent position and adjusts the detent position
to perform the control before and after the detent securely. If the adjustment is not performed, "the
positioner may not operate normally before and after the detent" or "the lever position for floating the boom
may be abnormal".
• If the work equipment starting current is not adjusted, "the dead zone of neutral may be wide" or "the work
equipment may generate large shocks when it starts/stops".
a For the adjustment procedure, see Testing and adjusting, "Boom raise adjustment", "Bucket tilt
adjustment", or "Bucket dump adjustment".
Swash plate control function of work equipment pump and steering
pump (WA470-PLT6-042-K-00-A)
• The control function of the swash plate of the work equipment pump and steering pump includes "Pickup
assistance control when engine speed is low" and "Overheat prevention control". The smaller pump
discharge (the command current to the swash plate angle control EPC valve is large) among the
calculation results of each control is selected.
Oil pressure - Flow characteristics when command current to swash plate angle control EPC valve of work
equipment pump is controlled
WA470-7 10-283
10 Structure and function
Work equipment control system
10-284 WA470-7
10 Structure and function
Work equipment control system
Function
• When the bucket is at the flat position or below, if the tilt lever is set in the detent position, the bucket stops
slowly at a set position.
1. Setting stop position
• The bucket stop position when the positioner is operated is changed with the bucket positioner
position set switch.
Condition for
Bucket lever is in Neutral and bucket is within ±5.5 degrees of setting angle.
enabling
Set the bucket to a desired position and push the bucket positioner switch. (less than
(1)
1 second)
Setting method The current bucket cylinder length is saved for the saved set position, and the setting
(2) completion buzzer sounds and the value is displayed on the monitor for 3 seconds.
(The set position is maintained even after the key is turned to the OFF position.)
To cancel the saved position (returned it to the default), hold down the bucket
(1)
positioner switch for 1 second or more.
Cancellation If within the set range, the position is set temporarily. However, the setting
method (2)
cancellation buzzer sounds 1 second after and the stop position is set to the default.
(3) The monitor displays the saved value (default: 0) for 3 seconds.
a The value displayed on the monitor is indication of a level and does not match to the actual bucket
angle.
a The bucket-equivalent angle means a calculated bucket angle. It does not always match to the
actual angle because of the shape of the bucket.
2. Cancellation of tilt detent
• When the bucket lever is in the tilt detent position, if the cylinder reaches the detent cancellation
position, the detent is canceled and the bucket stops slowly.
3. Stopping tilting (slowly)
• Tilting (slow) stop function decreases the speed of tilting within the range of 100 to 7 mm before the
target stop position by feeding back the cylinder length, corresponding to the stopping angle.
• After the tilt detent is canceled, if the bucket lever is held in the tilt detent position, tilting is not
stopped (slowly) but accelerated from the time when the lever is judged to be held, in the return
modulation at the target flow set with the lever.
WA470-7 10-285
10 Structure and function
Work equipment control system
• Accordingly, if the detent is held with the bucket positioner operated and the bucket is operated
over the stop position, the bucket tilting is decelerated temporarily and then accelerated.
4. Detent operation while engine is stopped
• While the engine is stopped, the detent is kept OFF, thus the lever is not held in the detent position
while the engine is stopped.
5. Adjustment of bucket angle
• The work equipment controller has a function to correct the cylinder length when the bucket is in
the flat position.
• As for the flat position of the bucket, one of the three positions A, B, and C can be saved according
to the attachment.
a For details of adjustment procedure, see "Bucket flat level adjustment" of "Explanation of components",
"Operation" in the Operation and maintenance manual.
Function
Raising kick-out (When pilot lamp lights up to indicate that only raising is effective or both raising and lowering
are effective)
• If the boom lever is set in the "Raising detent" position, the boom starts deceleration before the set
position, cancels the raising detent, and controls stopping (slowly).
• When the boom is not in the "Raising detent" position, it is raised by the operator's operation.
• If raising is not selected, only the raising detent operates.
• If the detent is turned ON, the remote positioner does not operated and only the kick-out function operates
(the boom stops at the top).
Stopping boom lowering (When pilot lamp lights up to indicate that only lowering is effective or both raising
and lowering are effective)
• If the boom lever is set in the "Floating detent" position, the boom starts deceleration before the set
position, cancels the floating detent, and controls stopping (slowly).
• If the boom lever is kept as it is, the boom starts lowering again.
• If lowering is not selected, only the floating detent operates.
• If the detent is turned ON when the boom angle is flat or below, the remote positioner does not operate
and only the floating detent function operates (the boom does not stop automatically).
a If the detent is turned ON when the boom is flat or below, the lowering remote positioner does not function
as the positioner and does not stop the boom, for distinction from the floating operation in the grading
work.
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10 Structure and function
Work equipment control system
a The floating detent does not operate at around the setting stop position. However, the floating detent
operates when the boom angle is below -37 degrees for the grading work.
1. Setting stop position
• The boom stop position when the positioner is operated is changed with the boom positioner switch.
WA470-7 10-287
10 Structure and function
Work equipment control system
• The semi auto-digging function uses only the kickdown switch and boom raising operation for the ease of
digging work. With this function, even an unskilled operator can improve the working efficiency. This
function has two modes of LOOSE and ROCK, either of which is selected according to the properties of
the objective material.
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10 Structure and function
Work equipment control system
• A bucket automatic operation pattern matched to the working cycle and load is selected.
Mode selection
No. Objective material Mode
1 Gravel/Sand LOOSE mode
2 Quarry/Blasted rocks ROCK mode
WA470-7 10-289
10 Structure and function
Work equipment control system
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10 Structure and function
Work equipment control system
Input/output signal
a. CAN signal
b. Emergency steering manual operation signal
c. Steering pump oil pressure signal
d. Emergency steering relay signal
e. Emergency steering pump oil pressure signal
f. Sensor power supply
Function
• The condition of the oil pressure sensors in the steering circuit is constantly monitored. When the steering
oil pressure decreases and the transmission output shaft speed (travel speed) increases above the
emergency steering "ON" value in the following figure, the emergency steering operation signal is output
to the emergency steering switch relay to operate the emergency steering.
• The emergency steering motor can be operated by operating the emergency steering switch, regardless
of the steering oil pressure or transmission output shaft speed (travel speed).
WA470-7 10-291
10 Structure and function
Work equipment control system
a The continuous operation time with the emergency steering switch must be limited within 60 seconds.
a The travel speed must be kept 5 km/h or below while the emergency steering is operated.
The conditions of the input and output signals of the controller can be checked with the monitoring function of
the machine monitor.
a For the monitoring procedure, see Testing and adjusting, “Special functions of machine monitor“.
Self-diagnosis function of work equipment controller (WA380-PTLC-042-K-00-A)
• The work equipment controller constantly monitors the input and output conditions and performs self-
diagnosis of the system.
• If any failure is detected by the self-diagnosis, its information is sent to the machine monitor via the
network.
• If any failure occurs, it can be checked with the machine monitor / KOMTRAX.
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10 Structure and function
Machine monitor system
Function (WA380-Q170-042-K-00-A)
• The machine monitor system mainly consists of the machine monitor, monitor controller, and switch panel.
1. Machine monitor
WA470-7 10-293
10 Structure and function
Machine monitor system
Data sent
Updated every 10 msec (RTCDB/r)
No. Item
1 Fan reverse set condition (reverse time)
2 Fan reverse set condition (interval time)
3 Fan manual selection (forward/reverse) enabled/disabled
4 Air conditioner Compressor Status
5 Attachment flow mode
6 Attachment flow level
7 Attachment set switch information
Updated every 100 msec (RTCDB/r)
No. Item
1 Service meter reading
2 Semi-auto digging mode setting
3 Auto-deceleration enabled/disabled setting
4 Parking brake operation
5 Adjustment ID
6 Adjustment switch information
7 Data for adjustment
8 Auto-kickdown enabled/disabled
9 Machine model data
10 Option data
11 Brake oil pressure (front)
12 Brake oil pressure (rear)
13 Idle stop set time
14 In-idle stop service mode flag
15 Idle stop set entry signal
16 Preheat condition
17 Engine speed fixing control command
18 Bucket flat level adjustment selection information
19 Bucket flat level adjustment initialization command
20 Recirculation air temperature
21 Set temperature
22 Air conditioner setting
Data received
Updated every 10 msec (RTCDB/r)
No. Item
1 Engine speed
2 Final injection rate
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10 Structure and function
Machine monitor system
No. Item
3 1st throttle position (accelerator pedal)
4 Engine condition
5 Key switch ACC terminal (engine controller)
6 Throttle correction value
7 Throttle upper limit value
8 Throttle lower limit value
9 Dynamic torque request
10 Torque curve selection
11 Droop type selection
12 Droop switch selection
13 ABS droop trim
14 Automatic warm-up cancel flag
15 Machine safety state 1
16 Machine safety state 2
17 Engine speed control flag
18 Travel speed (tire diameter and correction counted in)
19 Actual gear speed display (F)
20 Actual gear speed display (N)
21 Actual gear speed display (R)
22 Actual gear speed display (1st)
23 Actual gear speed display (2nd)
24 Actual gear speed display (3rd)
25 Actual gear speed display (4th)
26 Directional lever display (F)
27 Directional lever display (N)
28 Directional lever display (R)
29 Shift range display (1st)
30 Shift range display (2nd)
31 Shift range display (3rd)
32 Shift range display (4th)
33 Transmission controller recognition lever direction
34 Working situation discrimination status
35 ECSS switch condition
36 Rim pull
37 Engine output mode
38 Engine output mode (Engine output mode condition in transmission controller)
39 Engine output mode selection
40 Throttle lock (RPM set) lower limit command value
41 Engine start permission flag
42 Boom lever condition
43 Bucket lever condition
44 Working condition check
45 Target rim pull
46 Scrape-up flag
47 Digging flag
48 Loader pump neutral flag
49 Steering pump neutral flag
50 Boom angle
51 Boom bottom pressure
52 Boom head pressure
53 Bell crank angle
54 Key SIG condition (ACC)
WA470-7 10-295
10 Structure and function
Machine monitor system
No. Item
55 Auto-kickdown work equipment posture sensing information
56 Depressing right brake pedal
Updated every 100 msec (RTCDB/r)
No. Item
1 Engine coolant temperature
2 Overrun condition
3 Grid heater control condition
4 Instantaneous fuel consumption
5 Soot accumulation level
6 KDPF regeneration mode
7 Manual regeneration permission condition
8 Thermal management auxiliary request
9 HC desorb flag
10 Hydraulic oil temperature
11 Torque converter oil temperature
12 AJSS indicator or FNR switch
13 Auto shift condition
14 Shift hold condition
15 Lockup operation condition
16 Fan reverse pilot lamp
17 Kickdown switch condition
18 Kickdown information
19 Transmission cut-off point setting buzzer operation
20 Lockup function switch
21 Left brake pressure
22 Idle stop remaining time
23 Idle stop condition
24 Cut-off switch built-in indicator condition
25 Semi-auto digging condition
26 Multicoulper operation condition
27 Throttle lock (RPM set) operation condition
28 Boom positioner operation condition
29 Positioner setting buzzer operation
30 Emergency steering motor operation condition
31 All work equipment lever neutral flag
32 Work equipment pump relief flag
33 AJSS warning
34 ATT (PCS) detent condition
35 ATT (PCS) mode (flow mode) condition
36 ATT (PCS) flow rate level
37 Bucket selection information
38 Work equipment lock indicator
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10 Structure and function
Machine monitor system
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10 Structure and function
Machine monitor system
Input/Output
Pin No. Signal name
Signal
7 LC unit backlight ON/OFF control Input
8 LC unit temperature sensor Input
AMP-6P [ CN-MDM2] (for LED unit)
Input/Output
Pin No. Signal name
Signal
1 LED unit power supply (+12 V) Input
2 LED unit power supply return GND ―
3 LIN Input/Output
4 LED unit power supply (+5 V) Input
5 (*1)
6 GND
AMP-8P [ CN-MDM3] (for meter unit)
Input/Output
Pin No. Signal name
Signal
1 Meter unit power supply (battery direct 24 V) Input
2 Key switch ACC terminal Input
3 CAN (+) Input/Output
4 Meter unit power supply return GND ―
5 Monitor brightness selector switch (night mode signal) Input
6 (*1)
7 CAN2 terminating resistor Input
8 CAN (-) Input/Output
*1: Never connect these pins. Malfunctions or failures may occur.
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10 Structure and function
Machine monitor system
Display (WA470-Q1LA-042-K-00-A)
WA470-7 10-299
10 Structure and function
Machine monitor system
A: Standard screen
B: ECO guidance screen
C: Maintenance time warning screen
D: Warning screen
E. Bucket positioner pop-up screen
F: User menu screen
1. Speedometer
2. Engine tachometer
3. Centralized warning lamp
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10 Structure and function
Machine monitor system
WA470-7 10-301
10 Structure and function
Machine monitor system
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10 Structure and function
Machine monitor system
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10 Structure and function
Machine monitor system
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10 Structure and function
Machine monitor system
Centra-
Monitor Item Display Action lized Alarm
display displayed warning Remarks
color level buzzer
lamp
• Notice time can be changed
in service menu
"Mmaintenance Mode
Setting" o "Maintenance
ModeChange" o
"Maintenance Notice Time
Setting".
Q
L04 Q (continu-
Engine ous)
Red Q • Appears when error is
system detected in engine system.
error L03 Q (intermit-
tent)
Yellow L01 ― ―
Q
L04 Q (continu-
Defective ous)
Red Q • Appears when error is
KDPF
(intermit- detected in KDPF system.
system L03 Q
tent)
Yellow L01 ― ―
KDPF soot Q • Appears when much soot is
accumula- Red L03 Q (intermit- accumulated in KDPF or
tion tent) system error including
caution lowered purification function
Yellow L01 ― ―
icon is detected.
Q
• Appears when engine speed
L02 Q (intermit-
is 2,525 rpm or above.
Engine tent)
Red Q
overrun
• Appears when engine speed
― Q (intermit-
is 2,425 rpm or above.
tent)
Radiator
― ― • Lights up when radiator
coolant Yellow L01
coolant level is low.
level
WA470-7 10-305
10 Structure and function
Machine monitor system
Centra-
Monitor Item Display Action lized Alarm
display displayed warning Remarks
color level buzzer
lamp
Steering
system • Appears when error is
error Yellow L01 ― ―
detected in steering system.
caution
icon
Emergen- Q
cy steering Red L03 Q (intermit-
system tent) • Appears when error is
error detected in emergency
caution steering system.
icon (if Yellow L01 ― ―
equipped)
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10 Structure and function
Machine monitor system
a If three or more cautions are occurring, the icons displayed are changed two by two every 2 seconds.
WA470-7 10-307
10 Structure and function
Machine monitor system
Headlamp
Blue Lights up when headlamp (high
(high
(LED) beam) is turned on.
beam)
Message
Back- Lights up when there is message • Goes out when answer is
(read but
ground: read but not returned yet. sent or validity of message
unre-
Black expires.
turned)
10-308 WA470-7
10 Structure and function
Machine monitor system
2-stage
low idle (if Lights up when 2-stage low idle is
Green
equipped) effective.
Remote
Green Lights up when lower stop is set.
positioner
Work
Lights up when work equipment is
equipment Red
locked.
lock
WA470-7 10-309
10 Structure and function
Machine monitor system
Green
Lights up when E mode is selected
E mode with power mode selector switch.
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10 Structure and function
Machine monitor system
WA470-7 10-311
10 Structure and function
Machine monitor system
Clear average fuel Clears average fuel consumption • User menu "ECO guidance" →
consumption logs logs "Average fuel consumption logs"
Select average
Selects 1-hour/1-day average fuel • User menu "ECO guidance" →
fuel consumption
consumption log "Average fuel consumption logs"
log
Initialize screen Returns to monitor screen brightness • User menu "Monitor setting" →
brightness to initial level "Screen adjustment"
Clear saved
Clears monitoring item • Service menu "Monitoring"
monitoring item
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10 Structure and function
Machine monitor system
Change between
Changes plus or minus of input value • Service menu "Adjusting"
plus and minus
WA470-7 10-313
10 Structure and function
Machine monitor system
10-314 WA470-7
10 Structure and function
Machine monitor system
a For operating method of the service mode functions, see "Service mode" section in Testing and adjusting.
WA470-7 10-315
10 Structure and function
Machine monitor system
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10 Structure and function
Rear view monitor system
Function (HM300-Q162-042-K-00-A)
• The rear view monitor system mainly consists of the rear view monitor, rear view camera, and monitor
controller.
1. Rearview monitor
Displays the rear view camera image to the operator according to the setting of the rear view monitor
controller (guide lines, display of reverse-interlock, luminance, etc.)
2. Rear view camera
Transmits the taken images to the rear view monitor.
3. Monitor controller
Sends the contents of change of the rear view monitor setting to the monitor.
WA470-7 10-317
10 Structure and function
Rear view monitor system
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10 Structure and function
Rear view monitor system
WA470-7 10-319
10 Structure and function
KOMTRAX system
• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, and GPS antenna.
• This system transmits various machine information by use of the radio communication. KOMTRAX
operator can refer this information and provide various services to the customers.
• Following information can be transmitted from the KOMTRAX system.
1. Position information
2. Operation information (service meter, odometer, etc.)
3. Alarm and failure information
4. Fuel consumption information
5. Maintenance information
6. Machine working condition information
a To provide the services, you need to establish radio station for KOMTRAX separately.
KOMTRAX terminal (HM300-Q220-042-K-00-A)
Model: TC330
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10 Structure and function
KOMTRAX system
CN1A[CN-KOM1]
Input/output
Pin No. Signal name
signal
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 CAN2_H Input/Output
11 CAN2_L Input/Output
12 (*1) —
13 (*1) —
14 External starting signal Input/Output
15 System operating lamp Output
16 (*1) —
17 (*1) —
18 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
CN1B[CN-KOM2]
Input/output
Pin No. Signal name
signal
1 GND (continuous power supply) —
2 GND (continuous power supply) —
3 Starting switch ACC signal Input
4 Alternator R signal Input
5 (*1) —
6 Continuous power supply (24 V) Input
7 Continuous power supply (24 V) Input
8 (*1) —
9 (*1) —
10 (*1) —
11 Starting switch C signal Input
12 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
Function (D65-Q220-042-K-01-A)
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of “KOMTRAX setting“ in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
WA470-7 10-321
10 Structure and function
KOMTRAX system
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.
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System component parts
WA470-7 10-323
10 Structure and function
System component parts
10-324 WA470-7
10 Structure and function
System component parts
WA470-7 10-325
10 Structure and function
System component parts
10-326 WA470-7
10 Structure and function
System component parts
WA470-7 10-327
10 Structure and function
System component parts
10-328 WA470-7
10 Structure and function
System component parts
WA470-7 10-329
10 Structure and function
System component parts
10-330 WA470-7
10 Structure and function
System component parts
WA470-7 10-331
10 Structure and function
System component parts
10-332 WA470-7
10 Structure and function
System component parts
WA470-7 10-333
10 Structure and function
System component parts
10-334 WA470-7
10 Structure and function
System component parts
WA470-7 10-335
10 Structure and function
System component parts
10-336 WA470-7
10 Structure and function
System component parts
a Do not disassemble this lever since it needs to be adjusted for maintaining the performance after
reassembly.
1. Boot
2. Sensor
WA470-7 10-337
10 Structure and function
System component parts
3. Detent solenoid
4. Connector
Function (WA380-PK11-042-K-02-A)
10-338 WA470-7
10 Structure and function
System component parts
• The control lever is held at the three operation stroke ends of "Boom LOWER", "Boom RAISE", and
"Bucket TILT". (Electric detent)
• Free return
Output voltage characteristics
• The operating angle (stroke) of the control lever is detected with the sensor and signal voltages are output
to the controller.
• Each sensor outputs two signal voltages which are opposite to each other as shown in the figure.
WA470-7 10-339
10 Structure and function
System component parts
10-340 WA470-7
10 Structure and function
System component parts
1. Pedal
2. Connector
3. Sensor
Function (WA470-AG22-042-K-00-A)
• This sensor, installed to the floor top, outputs accelerator signals and idle validation signals according to
the depressing angle of the accelerator pedal.
Accelerator signal
• The potentiometer in the sensor detects displacement of the accelerator pedal and outputs the variable
voltage through pin No. 2.
WA470-7 10-341
10 Structure and function
System component parts
Output characteristics
10-342 WA470-7
10 Structure and function
System component parts
Structure
• The directional lever has three positions and the gear speed switch has four positions. The switch itself
does not have a detent mechanism, which is in the combination switch. Each switch is positioned with
pins at two places and fixed to the body with three screws. When each lever is operated to a desired
position, the switch connected with the shaft moves to supply the current to only its circuit.
Function (WA380-CX10-042-K-00-A)
WA470-7 10-343
10 Structure and function
System component parts
Operation (WA380-CX10-044-K-00-A)
• When directional lever (1) of the combination switch is operated, body (2) rotates.
• Slider (4) moves on control switch (5) via arm (3) of body (2). Slider (4) has magnet (6) in it.
• Control switch (5) has Hall elements (7), which are arranged on the circuit board and matched to each
position of forward and reverse travels.
• If the combination switch senses that magnet (6) comes just above Hall element (7) at each position, it
outputs the "F (Forward)", "N (Neutral)", or "R (Reverse)" signal according to the operation of directional
lever (1).
• At the same time, slider (9) moves on control switch (5) via arm (8) of body (2). Slider (9) has magnet (10)
in it.
• Hall elements (11) built in control switch (5) are arranged respectively on the circuit boards at each
position of forward and reverse travels and at the intermediate position between them.
• Hall elements (11) are in the voltage signal output circuit. When it is sensed that magnet (10) comes just
above each Hall element (11), the output signal voltage changes.
• The combination switch changes the output voltage of the analogue backup signal according to the
position of directional lever (1).
• If gear speed switch (13) is rotated around shaft (12) of the combination switch, slider (16) moves on
control switch (5) via shaft (14) and arm (15) connected to gear speed switch (13). Slider (16) has magnet
(17) in it.
• Control switch (5) has Hall elements (18), which are arranged on the circuit board and matched to each
position of the gear speeds.
• If the combination switch senses that magnet (17) comes just above Hall element (18) at each position, it
outputs the "1st", "2nd", "3rd", or "4th" signal according to the operation of gear speed switch (13).
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10 Structure and function
System component parts
Function (WA380-CP22-042-K-00-A)
• Switch A (1) installed to the boom control lever knob operates as a kickdown switch to downshift the gear.
• Switch A (1) is a momentary type switch, namely, its contacts are closed only while it is pressed.
Hold switch (WA380-CP25-001-K-00-A)
2-lever type (WA380-CP25-041-K-00-A)
WA470-7 10-345
10 Structure and function
System component parts
Function (WA380-CP25-042-K-00-A)
• Switch B (2) installed to the boom control lever knob operates as a hold switch to hold the gear speed in
the auto-shift mode.
• Switch B (2) is a momentary type switch, namely, its contacts are closed only while it is pressed.
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10 Structure and function
System component parts
Specifications (PC220-Q2V1-030-K-00-A)
Resistance: 120 z
Function (PC220-Q2V1-042-K-00-A)
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.
Front brake oil pressure switch (WA380-G41C-041-K-00-A)
1. Switch
2. Connector
Specification (WA380-G41C-030-K-00-A)
Contact type: Normally open
Operating (ON) pressure: 5.39 ± 0.49 MPa {55 ± 5 kg/cm2}
Resetting (OFF) pressure: 4.41 ± 0.49 MPa {45 ± 5 kg/cm2}
Function (WA380-G41C-042-K-00-A)
• This sensor, installed to the inlet port of the front brake accumulator, senses the charge pressure in the
front brake circuit and turns the switch "ON" when the pressure exceeds the specified level.
WA470-7 10-347
10 Structure and function
System component parts
1. Switch
2. Connector
Specification (WA380-G41E-030-K-00-A)
Contact type: Normally open
Operating (ON) pressure: 5.39 ± 0.49 MPa {55 ± 5 kg/cm2}
Resetting (OFF) pressure: 4.41 ± 0.49 MPa {45 ± 5 kg/cm2}
Function (WA380-G41E-042-K-00-A)
• This sensor, installed to the inlet port of the rear brake accumulator, senses the charge pressure in the
rear brake circuit and turns the switch "ON" when the pressure exceeds the specified level.
Stop lamp oil pressure switch (WA380-G7B4-041-K-00-A)
1. Switch
2. Connector
Specification (WA380-G7B4-030-K-00-A)
Contact type: Normally open
Operating (ON) pressure: 0.59 ± 0.098 MPa {6 ± 1.0kg/cm 2}
Resetting (OFF) pressure: 0.39 ± 0.049 MPa {4 ± 0.5 kg/cm2}
Function (WA380-G7B4-042-K-00-A)
• This sensor, installed to the brake valve, senses the actuating pressure in the brake circuit and turns the
switch "ON" when the pressure exceeds the specified level.
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10 Structure and function
System component parts
1. Switch
2. Connector
Specification (WA380-GP2F-030-K-00-A)
Contact type: Normally open
Operating (ON) pressure: 0.59 ± 0.049 MPa {6 ± 0.5 kg/cm 2}
Resetting (OFF) pressure: 0.39 ± 0.049 MPa {4 ± 0.5 kg/cm2}
Function (WA380-GP2F-042-K-00-A)
• This sensor, installed to the parking solenoid valve of the transmission control valve, senses the actuating
pressure in the parking brake circuit and turns the switch "ON" when the pressure exceeds the specified
level.
WA470-7 10-349
10 Structure and function
Sensor
Sensor (ALL-E700-001-P-00-A)
1. Connector
2. Sensor
Function (ENG-AAP2-042-K-00-A)
• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.
Output characteristics
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10 Structure and function
Sensor
1. Connector
2. Sensor
3. O-ring
Function (PC400-ABK5-042-K-00-A)
• This oil pressure sensor, installed in the cylinder block, It detects engine oil pressure to output variable
voltage.
Charge (Boost) pressure sensor (PC400-AAM3-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC400-AAM3-042-K-00-A)
• This sensor is installed to the engine intake manifold. It detects the engine boost pressure to output
signals as a variable voltage.
a a "Chargepressure" is the turbocharged pressure of a turbocharged engine. It is also referred to as a
"boost pressure".
WA470-7 10-351
10 Structure and function
Sensor
Function (D155-AAM4-042-K-00-A)
• The charge (boost) temperature sensor detects the intake air temperature (boost temperature) and sends
it to the engine controller.
• The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine
controller applies voltage to the thermistor and detects the temperature by the voltage divided by the
resistance in the computer and the resistance of the thermistor.
Coolant temperature sensor (ENG-BA87-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (WA470-BA87-042-K-00-A)
• This sensor, installed on the cylinder block of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
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Sensor
1. O-ring
2. Sensor
3. Connector
Function (WA470-AG42-042-K-00-A)
• This sensor, installed to the flywheel housing, outputs the pulse voltage according to the rotation of the
gear.
WA470-7 10-353
10 Structure and function
Sensor
Function (ENG125-AG62-042-K-00-A)
• Like the NE speed sensor, it utilizes 0 to 5 V pulses that result from the change in the magnetic lines
passing through the sensor.
• The disc gear installed to the central part of the camshaft of the high-pressure pump has teeth (cut parts)
around it at intervals of 120 deg.
• In addition to the above teeth, one more tooth is installed. Accordingly, seven pulses are generated every
two revolutions of the engine.
• The standard pulse of No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and
Bkup speed sensor pulse.
Common rail pressure sensor (ENG-AE28-041-K-00-A)
1. Connector
2. Sensor
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10 Structure and function
Sensor
Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.
EGR valve lift sensor (ENG125-A9S2-041-K-00-A)
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG125-A9S2-042-K-00-A)
• The sensor, installed to EGR valve on the engine, detects the EGR valve opening to output the
corresponding variable voltage.
Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.
WA470-7 10-355
10 Structure and function
Sensor
1. Sensor
2. O-ring
3. Connector
Function (ENG125-AAQ4-042-K-00-A)
• This sensor, installed to KVGT in the engine, outputs the pulse voltage by means of the rotation of KVGT
turbine.
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10 Structure and function
Sensor
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG-AAQ3-042-K-00-A)
• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.
Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.
WA470-7 10-357
10 Structure and function
Sensor
1. Connector
2. O-ring
3. Sensor
Function (ENG-A96H-042-K-00-A)
• This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The “MAF (Mass Air Flow)“ means the “intake air flow“.
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10 Structure and function
Sensor
1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor
Function (ENG-A9HL-042-K-00-A)
• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
corresponding variable voltage.
• The output pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
• The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).
WA470-7 10-359
10 Structure and function
Sensor
1. Sensor
2. Connector
Function (ENG-A9HG-042-K-00-A)
• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDOC outlet temperature sensor (ENG-A9HH-041-K-00-A)
1. Sensor
2. Connector
Function (ENG-A9HH-042-K-00-A)
• This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
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10 Structure and function
Sensor
1. Sensor
2. Connector
Function (ENG-A9HJ-042-K-00-A)
• This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.
Crankcase pressure sensor (ENG-A18C-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-A18C-042-K-00-A)
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
WA470-7 10-361
10 Structure and function
Sensor
1. Connector
2. Bracket
3. Float
4. Switch
Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns “OFF“ by the lowered float, if the oil level
becomes lower than specified.
Dosing fuel pressure sensor (PC400-A9JC-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC400-A9JC-042-K-00-A)
• This sensor, which is installed to the dosing fuel solenoid valve assembly, detects the pressure of the fuel
supplied to output the corresponding variable voltage.
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10 Structure and function
Sensor
1. Wire
2. Magnet
3. Housing
4. Connector
Function (WA470-CNB1-042-K-00-A)
• This sensor, installed to the left side of the transmission rear case, outputs the pulse voltage according to
the rotation of the gear.
WA470-7 10-363
10 Structure and function
Sensor
1. Wire
2. Magnet
3. Terminal
4. Housing
5. Connector
Function (WA470-CNA1-042-K-00-A)
• This sensor, installed to the right side of the transmission front case, outputs the pulse voltage according
to the rotation of the gear.
Cooling fan speed sensor (D65-B750-041-K-00-A)
1. Sensor
2. Connector
Function (D65-B750-042-K-00-A)
• This sensor is installed to the cooling fan motor.
• This sensor detects the gear speed and outputs corresponding pulse signals.
10-364 WA470-7
10 Structure and function
Sensor
1. Connector
2. Plug
3. Thermistor
Function (WA380-CDK4-042-K-00-A)
• This sensor is installed to the block on the right side of the transmission rear case. It outputs a resistance
change signal of the thermistor for the temperature change.
Transmission oil temperature sensor (WA380-CH18-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function (WA470-CH18-042-K-00-A)
• This sensor, installed to the transmission rear case, outputs a resistance change signal of the thermistor
for the temperature change.
WA470-7 10-365
10 Structure and function
Sensor
1. Connector
2. Plug
3. Thermistor
Function (WA380-PMT1-042-K-00-A)
• This sensor is installed to the block of the hydraulic tank return line. It outputs a resistance change signal
of the thermistor for the temperature change.
Brake oil temperature sensor (WA380-GGD1-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function (WA380-GGD1-042-K-00-A)
• This sensor is installed to the rear axle. It outputs a resistance change signal of the thermistor for the
temperature change.
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10 Structure and function
Sensor
1. Sensor
2. Lead wire
3. Connector
Function (WA470-CDL5-042-K-00-A)
• This sensor, installed to the block on the left side of the transmission rear case, detects the torque
converter in let pressure and outputs it as a variable voltage.
Output characteristics
WA470-7 10-367
10 Structure and function
Sensor
1. Sensor
2. Lead wire
3. Connector
Function (WA470-CDL6-042-K-00-A)
• This sensor, installed to the block on the right side of the transmission rear case, detects the torque
converter outlet pressure and outputs it as a variable voltage.
Output characteristics
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10 Structure and function
Sensor
1. Plug
2. Sensor
3. Connector
Function (WA380-PPD1-042-K-00-A)
• This sensor is installed to the work equipment control valve. It senses the pump delivery pressure and
outputs a variable voltage for it.
Output characteristics
WA470-7 10-369
10 Structure and function
Sensor
1. Plug
2. Sensor
3. Connector
Function (WA380-F7C1-042-K-00-A)
• This sensor is installed to the block of the steering pump delivery line. It senses the pump delivery
pressure and outputs a variable voltage for it.
Output characteristics
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10 Structure and function
Sensor
1. Plug
2. Sensor
3. Connector
Function (WA380-F9SA-042-K-00-A)
• This sensor, installed to the block of the emergency steering pump discharge port, detects the pump
discharge pressure and outputs a variable voltage for it.
Output characteristics
WA470-7 10-371
10 Structure and function
Sensor
1. Plug
2. Sensor
3. Connector
Function (WA380-L261-042-K-00-A)
• This sensor is installed to the line piping of the lift cylinder bottom. It senses the oil pressure in the cylinder
bottom and outputs a variable voltage for it.
Output characteristics
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Sensor
1. Sensor
2. Lead wire
3. Connector
Function (WA380-CP61-042-K-00-A)
• This sensor is installed to the front brake circuit tube under the floor. It senses the brake actuating
pressure and outputs a variable voltage.
Output characteristics
WA470-7 10-373
10 Structure and function
Sensor
1. Reservoir tank
2. Float
3. Sensor
4. Connector
Function (WA380-B252-042-K-00-A)
• This sensor is installed to the ladder on the right side of the machine. When the coolant level lowers below
the specified level, the float of this sensor lowers and turns the switch "OFF".
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Sensor
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
Function (WA380-AD41-042-K-00-A)
• This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level. The movement of the float moves the variable resistor through the arm and the resistance
change is converted into the change of the power supply voltage, which is output as a signal voltage.
WA470-7 10-375
10 Structure and function
Sensor
1. Boss
2. Switch
3. Conduit
4. Wire
5. Connector
Function (PC-A968-042-K-00-A)
• This sensor is installed on the air cleaner outlet side. The switch is turned to “ON“ position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).
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10 Structure and function
Sensor
1. Shaft
2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector
Function (WA380-L6W6-042-K-00-A)
• This potentiometer is installed to the front frame. The movement of the boom moves the variable resistor
through the link installed to the boom and the resistance change is converted into the change of the power
supply voltage, which is output as a signal voltage.
Output characteristics
WA470-7 10-377
10 Structure and function
Sensor
1. Shaft
2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector
Function (WA380-LENB-042-K-00-A)
• This potentiometer is installed to the pin connecting bell crank and boom. The movement of the bucket
moves the variable resistor through the link installed to the bell crank and the resistance change is
converted into the change of the power supply voltage, which is output as a signal voltage.
Output characteristics
10-378 WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model Serial Number
WA470-7 20-1
20 Standard value tables
Table of contents
20-2 WA470-7
20 Standard value tables
Standard value table for engine
Standard value
Item Measurement condition Unit for new Repair limit
machine
pressure • Engine speed: 200 to 280 pressure {kg/cm2} {Min. 30} {20}
rpm
• Coolant temperature: 60 to 102°C
• Torque converter oil temperature: 60 to 80° kPa
Blowby Max. 1.96 3.92
pressure C {mmH2-
• With torque converter stalled {Max. 200} {400}
O}
• KCCV circuit disconnected
• Coolant temperature: Min. MPa 0.29 to 0.69 0.18
60°C High idle
{kg/cm2} {3.0 to 7.0} {1.8}
Engine oil • EOS5W30-LA
pressure • EOS5W40-LA MPa Min. 0.08 0.05
• EO10W30-LA Low idle
{kg/cm2} {Min. 0.8} {0.5}
• EO15W40-LA
EGR valve oil MPa Min. 1.43 1.43
High idle
pressure and • Coolant temperature: 60 to {kg/cm2} {Min. 14.6} {14.6}
KVGT oil 102°C MPa Min. 1.18 1.18
pressure Low idle
{kg/cm2} {Min. 12.0} {12.0}
Oil
Whole speed range (inside oil pan) °C 90 to 110 120
temperature
• Between crankshaft pulley and alternator
Alternator belt pulley
mm 13 to 16 13 to 16
tension • Deflection when pressed with finger at 59
N {6 kg}
WA470-7 20-3
20 Standard value tables
Standard value table for engine
Standard value
Item Measurement condition Unit for new Repair limit
machine
Standard value
Item Measurement condition Unit for new Repair limit
machine
20-4 WA470-7
20 Standard value tables
Standard value table for machine
WA470-7 20-5
20 Standard value tables
Standard value table for machine
- -
HOLD
LOWER o 11.4 to 20.2
• Engine speed: Low idle N {kg} Max. 30.3 {3.09}
FLOAT {1.16 to 2.06}
FLOAT (*2) o 9.8 to 20.6 4.9 to 30.5
HOLD {1.0 to 2.0} {0.5 to 3.11}
HOLD o 7.5 to 17.7
Max. 26.6 {2.7}
DUMP {0.76 to 1.80}
HOLD o TILT 6.5 to 11.4
Bucket Max. 17.1 {1.74}
(*1) {0.66 to 1.16}
TILT (*2) o 9.8 to 20.6 4.9 to 30.5
HOLD {1.0 to 2.10} {0.5 to 3.11}
HOLD io
RAISE (*2) 44.5 ± 2.2 44.5 ± 4.4
HOLD io
Boom 31.2 to 37.9 Min. 31.2
LOWER (*1)
Stroke
20-6 WA470-7
20 Standard value tables
Standard value table for machine
Accelerator pedal
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Start engine. 45.5 to 58.8
Depressing effort • Measure at 150 mm away N {kg} -
from pedal fulcrum {4.64 to 6.00}
NEUTRAL
Depressing a For details, see Fig. A at end 45 ± 2 -
(a1) deg.
angle of this section
Max. (a2) • Start engine. 17 ± 2 -
Brake pedal
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
323 ± 30 Min. 264
Depressing effort N {kg}
a For details, see Fig. B at the {32.9 ± 3.0} {Min. 26.9}
NEUTRAL end of this section
Depressing 53 -
(a1) • Engine speed: Low idle
angle • Hydraulic oil temperature: 45 deg.
Max. (a2) 15 (+1 / 0) -
Play to 55°C -
5±1
Tire
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
A Max. 2.5 -
Fitting of wheel lock ring a For details, see Fig. C at end
B of this section. Max. 4.0 -
mm
Clearance of wheel lock
ring C • Tire inflation pressure: 2 to 10 -
Specified pressure
Engine speed
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Hydraulic oil E mode 1,710 ± 50 1,710 ± 100
Torque converter stall temperature: 60 to P mode 1,785 ± 50 1,785 ± 100
Hydraulic stall 102°C E mode 1,825 ± 100 1,825 ± 200
• Torque converter
Bucket CURL relief oil temperature: 60 P mode rpm 2,110 ± 100 2,110 ± 200
to 80°C E mode 1,555 ± 100 1,555 ± 200
Torque converter stall and
hydraulic relief speed • Hydraulic oil
temperature: 45 to P mode 1,645 ± 100 1,645 ± 200
Bucket CURL relief
55°C
WA470-7 20-7
20 Standard value tables
Standard value table for machine
Steering
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
24.5 (+1.23 /
• Hydraulic oil temperature: 45 24.5 ± 1.23 -2.45)
Steering relief pressure to 55°C
• Engine speed: High idle MPa {250 ± 12.5} {250 (+12.5 /
-25)}
{kg/
• Hydraulic oil temperature: 45 cm2}
to 55°C 1.25 to 1.45 1.15 to 1.55
Steering control pressure
• Engine speed: Low idle {12.7 to 14.8} {11.7 to 15.3}
• Steering wheel: Free
20-8 WA470-7
20 Standard value tables
Standard value table for machine
Accumulator
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Checking to
be
performed
when the 5.9 (+0.98 /
• Engine 5.9 (+0.5 / 0)
Charge cut-in pressure brake oil -0.5)
speed: Low pressure {60 (+5 / 0)}
{60 (+10 / -5)}
idle warning MPa
• Hydraulic lamp goes {kg/
oil off cm2}
tempera- • Measure
ture: 45 to when brake
55°C oil pressure 9.8 (+0.98 / 0) 9.8 (+1.5 / -0.5)
Charge cut-out pressure
starts {100 (+10 / 0)} {100 (+15 / -5)}
lowering
after rising.
WA470-7 20-9
20 Standard value tables
Standard value table for machine
Power train
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
1st speed 7.6 ± 0.4 7.6 ± 0.5
2nd
speed 13.1 ± 0.7 13.1 ± 0.9
P mode
3rd
speed 22.9 ± 1.1 22.9 ± 1.6
4th speed 36.2 ± 1.8 36.2 ± 2.5
Forward
1st speed 6.6 ± 0.3 6.6 ± 0.5
2nd
speed 11.4 ± 0.6 11.4 ± 0.8
E mode
3rd
speed 19.6 ± 1.0 19.6 ± 1.4
Travel speed
4th speed 30.8 ± 1.5 30.8 ± 2.2
(bucket empty) km/h
1st speed 7.9 ± 0.4 7.9 ± 0.6
(Lockup clutch: OFF)
2nd
speed 13.5 ± 0.7 13.5 ± 0.9
P mode
3rd
speed 23.6 ± 1.2 23.6 ± 1.7
4th speed 37.3 ± 1.9 37.3 ± 2.6
Reverse
1st speed 6.8 ± 0.3 6.8 ± 0.5
2nd
speed 11.7 ± 0.6 11.7 ± 0.8
E mode
3rd
speed 20.2 ± 1.0 20.2 ± 1.4
4th speed 31.7 ± 1.6 31.7 ± 2.2
1st speed 7.6 ± 0.4 7.6 ± 0.5
2nd
speed 13.2 ± 0.7 13.2 ± 0.9
P mode
3rd
speed 23.6 ± 1.2 23.6 ± 1.7
4th speed 38.3 ± 1.9 38.3 ± 2.7
Forward
1st speed 6.6 ± 0.3 6.6 ± 0.5
2nd
speed 11.5 ± 0.6 11.5 ± 0.9
E mode
3rd
speed 20.4 ± 1.0 20.4 ± 1.5
Travel speed
4th speed 33.1 ± 1.7 33.1 ± 2.4
(bucket empty) km/h
1st speed 7.9 ± 0.4 7.9 ± 0.6
(Lockup clutch: ON)
2nd
speed 13.7 ± 0.7 13.7 ± 0.9
P mode
3rd
speed 24.3 ± 1.2 24.3 ± 1.7
4th speed 39.0 ± 2.0 39.0 ± 2.8
Reverse
1st speed 6.8 ± 0.3 6.8 ± 0.5
2nd
speed 11.8 ± 0.6 11.8 ± 0.9
E mode
3rd
speed 21.1 ± 1.1 21.1 ± 1.6
4th speed 34.2 ± 1.7 34.2 ± 2.4
20-10 WA470-7
20 Standard value tables
Standard value table for machine
Wheel brake
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Hydraulic oil temperature: 45 4.8 ± 0.4 Min. 4.2
Brake oil pressure
to 55°C {48.9 ± 4.1} {Min. 42.7}
• Engine stopped MPa
• Measure lowering of oil {kg/
Max. 0.49 Max. 0.49
Drop of brake oil pressure pressure after depressing cm2}
brake pedal for 5 min with 4.9 Max. {5.0} Max. {5.0}
MPa {50 kg/cm2}
• Tire inflation pressure:
Specified pressure
• Flat, level, straight, and dry
paved road
• Travel speed at beginning of
brake application 20 km/h:
Performance Delay in applying brakes m Max. 5 Max. 5
Max. 0.1sec.
• Brake pedal depressing
force:
Specified depressing effort
323 ± 30 N {32.9 ± 3 kg}
• Measure braking distance.
Shaft protrusion
• Oil pressure: 4.9 MPa {50 kg/ Protrusion of reaches wear
Wear of disc cm2} mm shaft limit position
• Pedal depressed completely 0 [Max. 2.4 mm]
Parking brake
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Torque converter oil Min. 2.32 Min. 2.32
Parking brake oil pressure MPa
temperature: 60 to 80°C {Min. 23.5} {Min. 23.5}
• Engine speed: Low idle {kg/
Parking brake solenoid valve Min. 2.32 Min. 2.32
• Parking brake: OFF cm2}
basic pressure {Min. 23.5} {Min. 23.5}
• Tire inflation pressure:
Specified pressure
• Flat paved road with a slope
of 1/5 (11 degrees 20') and
dry surface
Performance • Set machine in operating - Stopped Stopped
condition.
a For measuring posture, see
Figs. D and E at the end of
this section
Disc thickness mm 3.2 ± 0.08 2.97
WA470-7 20-11
20 Standard value tables
Standard value table for machine
20-12 WA470-7
20 Standard value tables
Standard value table for machine
Work equipment
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Hydraulic oil temperature: 45 34.3 (+1.8 /
Work equipment relief 34.3 ± 1.77
to 55°C -4.4)
pressure {350 ± 18}
• Engine speed: High idle {350 (+18 / -45)}
• Hydraulic oil temperature: 45
to 55°C 1.72 to 3.43 1.72 to 3.43
Unload pressure • Engine speed: High idle MPa
• Work equipment control {kg/ {17.5 to 35} {17.5 to 35}
lever: NEUTRAL cm2}
• Hydraulic oil temperature: 45
to 55°C 1.37 ± 0.1 1.37 ± 0.2
LS differential pressure • Engine speed: High idle
• Boom control lever: In {14 ± 1} {14 ± 2}
halfway
• Hydraulic oil E mode 6.3 ± 0.5 Max. 8.4
Boom RAISE temperature: 45 to P mode 5.9 ± 0.5 Max. 7.7
55°C E mode 3.1 ± 0.5 Max. 4.4
• Engine speed:
High idle
• Apply no load
Work equipment speed
Boom LOWER
a For measuring P mode 3.1 ± 0.5 Max. 4.0
posture, see Figs.
F and G at end of
this section sec.
• Hydraulic oil E mode 1.8 ± 0.3 Max. 2.4
Dump temperature: 45 to
Bucket full P mode 1.6 ± 0.3 Max. 2.1
stroke 55°C E mode 2.6 ± 0.3 Max. 3.5
Tilt back • Engine speed:
High idle P mode 2.4 ± 0.3 Max. 3.2
• Apply no load E mode 1.6 ± 0.3 Max. 2.1
Bucket from a For measuring
level position Tilt back posture, see Figs. P mode 1.5 ± 0.3 Max. 2.0
H and J at the end
of this section
Retraction of lift cylinder • Hydraulic oil temperature: 45
Max. 30 Max. 36
rod to 55°C
• Stop the engine and leave it
Hydraulic drift
WA470-7 20-13
20 Standard value tables
Standard value table for machine
Hydraulic fan
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Engine high idle
• Coolant temperature: Min.
95°C
Cooling fan maximum speed • Hydraulic oil temperature: 1,300 ± 100 1,300 ± 200
Min. 95°C
• Torque converter oil
temperature: Min. 105°C
• Engine low idle rpm
• Coolant temperature: Max. Air conditioner: Air conditioner:
70°C OFF OFF
• Hydraulic oil temperature: 175 ± 50 175 ± 100
Cooling fan minimum speed
Max. 70°C Air conditioner: Air conditioner:
• Torque converter oil ON ON
temperature: Max. 80°C 727 ± 50 727 ± 100
• Air conditioner: OFF
• Engine high idle
• Fan 100% mode (*) 14.3 ± 1.4 14.3 ± 2.1
Cooling fan drive pressure
• Hydraulic oil temperature: MPa {146 ± 15} {146 ± 22}
50°C
{kg/
• When cooling fan is reversed
Cooling fan reverse solenoid cm2} 2.51 ± 0.35 2.51 ± 0.53
• Engine high idle
output pressure • Hydraulic oil temperature: {25.6 ± 3.6} {25.6 ± 5.4}
50°C
*: Fan speed becomes 100% when it is set to reverse mode.
20-14 WA470-7
20 Standard value tables
Standard value table for machine
a Fig. A
a Fig. B
a Fig. C
WA470-7 20-15
20 Standard value tables
Standard value table for machine
a Fig. D
a Fig. E
a Fig. F
a Fig. G
20-16 WA470-7
20 Standard value tables
Standard value table for machine
a Fig. H
a Fig. J
a Fig. K
WA470-7 20-17
20 Standard value tables
Standard value table for electrical system
Controller (WA470-RA1E-033-K-00-A)
Equipment name Procedure, measuring location, criteria and remarks
1. Turn starting switch to the OFF position, and set battery disconnect switch to
the OFF position.
2. Insert T-adapter into EC3.
Continuous 3. Set battery disconnect switch to ON position.
Engine power 4. Measure voltage with starting switch at OFF position and when starting
controller supply engine.
voltage Between EC3 (1) and (21) 20 to 30 V
Between EC3 (2) and (22) 20 to 30 V
Voltage
Between EC3 (11) and (31) 20 to 30 V
Between EC3 (12) and (32) 20 to 30 V
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
Continuous 3. Insert T-adapter into connector L73.
power 4. Turn battery disconnect switch to ON position.
supply 5. Turn starting switch to ON position.
voltage Between L73 (1) and each of (21), (31), (32),
Voltage and (33), and between L73 (11) and each of 20 to 30 V
Work (21), (31), (32), and (33)
equipment 1. Turn starting switch to OFF position.
controller 2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector L73.
Solenoid 4. Turn battery disconnect switch to ON position.
power 5. Turn starting switch to ON position.
supply
Between L73 (2) and (21) 20 to 30 V
voltage
Between L73 (12) and (31) 20 to 30 V
Voltage
Between L73 (22) and (32), and between L73
(22) and (33) 20 to 30 V
20-18 WA470-7
20 Standard value tables
Standard value table for electrical system
WA470-7 20-19
20 Standard value tables
Standard value table for electrical system
20-20 WA470-7
20 Standard value tables
Standard value table for electrical system
WA470-7 20-21
20 Standard value tables
Standard value table for electrical system
20-22 WA470-7
20 Standard value tables
Standard value table for electrical system
WA470-7 20-23
20 Standard value tables
Standard value table for electrical system
20-24 WA470-7
20 Standard value tables
Standard value table for electrical system
WA470-7 20-25
20 Standard value tables
Standard value table for electrical system
20-26 WA470-7
20 Standard value tables
Standard value table for electrical system
WA470-7 20-27
20 Standard value tables
Standard value table for electrical system
20-28 WA470-7
20 Standard value tables
Standard value table for electrical system
WA470-7 20-29
20 Standard value tables
Standard value table for electrical system
20-30 WA470-7
20 Standard value tables
Standard value table for electrical system
WA470-7 20-31
20 Standard value tables
Standard value table for electrical system
20-32 WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model Serial Number
WA470-7 30-1
30 Testing and adjusting
Table of contents
30-2 WA470-7
30 Testing and adjusting
Table of contents
WA470-7 30-3
30 Testing and adjusting
General information on testing and adjusting
Q'ty
adjusting item Part No. Part name Remarks
bol
Testing boost -101 to 200 kPa {-760 to 1,500
A 799-201-2202 Boost gauge kit 1 mmHg}
pressure
1 799-201-9002 Handy smoke checker 1
Testing exhaust gas
C Commercially Bosch index: 0 to 9
color 2 Smoke meter 1
available
Testing and
Commercially Feeler gauge
adjusting valve D 1 1
available
clearance
1 795-502-1590 Gauge assembly 1
795-471-1420 Adapter 1
Testing compression 2
pressure E 6217-71-6112 Gasket 1
Commercially Inner diameter 14 mm, length
3 Hose 1 approx. 2 m
available
1 799-201-1504 Blowby checker 1 0 to 10 kPa {0 to 1,000 mmH2O}
Testing blowby
F 2 799T-201-3210 Plug 1 Hose inside diameter: 24 mm
pressure
3 799T-201-3220 Cap 2 Pipe outside diameter: 25.4 mm
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
{25, 60, 400, 600 kg/cm2}
Testing engine oil
pressure G Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
Pressure gauge: 1.0 MPa {10
3 799-401-2320 Gauge 1 kg/cm2}
795T-401-1310 Plug 1
1
02896-21018 O-ring 1
Testing EGR valve Pressure gauge: 2.5, 6.0, 40, 60
and KVGT oil H 2 799-101-5002 Hydraulic tester 1 MPa
pressure {25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
3 790-261-1204 Digital hydraulic tester 1 kg/cm2}
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
Testing fuel 2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
pressure J
795-790-5120 Screw 1 M14 x 1.5 o Rc1/8
3 07005-01412 Gasket 1
790-301-1530 Elbow 1 Rc1/8 x Rc1/8
4 799-401-2320 Gauge 1 1 MPa
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercially
3 Hose 1 Inside diameter: approx. 6 mm
Testing fuel available
discharge, return K Commercially
4 Hose 1 Inside diameter: approx. 16 mm
and leakage available
Commercially Measuring cylinder
5 1
available
Commercially Stopwatch
6 1
available
30-4 WA470-7
30 Testing and adjusting
General information on testing and adjusting
Q'ty
adjusting item Part No. Part name Remarks
bol
Developer for dye
Testing fuel circuit Commercially
L penetrant (color 1
for leakage available checker)
Testing directional
M 79A-264-0021 Push-pull scale 1
lever
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
{25, 60, 400, 600 kg/cm2}
Testing and Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1
adjusting power N kg/cm2}
train oil pressure Pressure gauge: 1.0 MPa {10
3 799-401-2320 Gauge 1 kg/cm2}
799-101-5220 Nipple 1 10 x 1.25 mm
4
07002-11023 O-ring 1
Retrieval of disabled
machine due to Plug
O 794-423-1190 1
transmission valve
failure
Testing steering
P 79A-264-0021 Push-pull scale 1
wheel
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
Testing and {25, 60, 400, 600 kg/cm2}
adjusting steering oil Q Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
pressure
799-101-5220 Nipple 1 10 x 1.25 mm
3
07002-11023 O-ring 1
Pressure gauge: 2.5, 6.0, 40, 60
Testing oil pressure 1 799-101-5002 Hydraulic tester 1 MPa
in cooling fan pump R {25, 60, 400, 600 kg/cm2}
circuit Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
Bleeding air from {25, 60, 400, 600 kg/cm2}
hydraulic fan circuit S
Pressure gauge: 40 MPa {400
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
3 790-261-1130 Coupling 1
Pressure gauge: 2.5, 6.0, 40, 60
Testing and
1 799-101-5002 Hydraulic tester 1 MPa
adjusting of
T {25, 60, 400, 600 kg/cm2}
accumulator charge
pressure Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
Testing lowering of 3 790-101-1102 Pump 1
wheel brake U 4 790-301-1720 Adapter 1 10 x 1.25 mm o R1/8
pressure 5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 Length: 5 m
7 790-261-1130 Coupling 1
Testing wear of Commercially Vernier calipers
V 1
wheel brake disc available
WA470-7 30-5
30 Testing and adjusting
General information on testing and adjusting
Q'ty
adjusting item Part No. Part name Remarks
bol
Pressure gauge: 2.5, 6.0, 40, 60
799-101-5002 Hydraulic tester 1 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing parking
brake oil pressure W Pressure gauge: 60 MPa {600
790-261-1204 Digital hydraulic tester 1 kg/cm2}
793T-615-1820 Adapter 1 10 x 1.25 mm
2
07002-11023 O-ring 1
Testing wear of Commercially
X Vernier calipers 1
parking brake disc available
Testing work 1 79A-264-0021 Push-pull scale 1
equipment control Y Commercially
lever 2 Ruler 1
available
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
Testing and {25, 60, 400, 600 kg/cm2}
adjusting work
equipment EPC oil Z Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
pressure
799-101-5220 Nipple 1 10 x 1.25 mm
3
07002-11023 O-ring 1
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
{25, 60, 400, 600 kg/cm2}
Testing and Pressure gauge: 60 MPa {600
adjusting work 2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
equipment oil ZA
pressure 799-101-5220 Nipple 1 10 x 1.25 mm
3
07002-11023 O-ring 1
Differential pressure
4 799-401-2701 gauge
1 401-799-2930 Adapter 1
Pressure gauge: 2.5, 6.0, 40, 60
Testing wheel brake 2 799-101-5002 Hydraulic tester 1 MPa
oil pressure ZB
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
3 790-261-1204 Digital hydraulic tester 1 kg/cm2}
Commercially Lap top type personal Windows XP SP2/VISTA/
1 computer 1
available Windows 7
2 Cu3886388 INSITE ver. 7.4 1
Writing
compensation 3 795-799-5730 INLINE 5 Kit 1
values at Commercially
ZC available
replacement of • Cable (USB)
injector and engine 4 • Cable (RS232) 1
or
controller 795-799-5740
5 795-799-5720 Cable (9P) 1
6 799-601-4510 Cable (12P) 1
Testing ECSS Commercially Gas charge tool
1 1
accumulator available
nitrogen gas Commercially Pressure reducing valve
2 1
pressure and available
procedure for ZD
charging Commercially
3 Charging hose 1
accumulator with available
nitrogen gas.
30-6 WA470-7
30 Testing and adjusting
General information on testing and adjusting
Q'ty
adjusting item Part No. Part name Remarks
bol
1 792-610-1702 Gas charge tool 1
Nipple
792-610-1310 1 GOST
(for Russia)
Testing brake Nipple
accumulator 792-610-1320 1 CGA No. 351
nitrogen gas (for US)
pressure and Nipple
procedure for ZE 792-610-1330 1 ASA B-571-1965
2 (for US)
charging DIN 477-7963
accumulator with Nipple
nitrogen gas. 792-610-1350 1 NEN 3268-1966
(for German)
SIS-SMS 2235/2238
Nipple BS 341
792-610-1360 1
(for UK) Part1-1962
Removal and
installation of — 795T-981-1010 Socket 1
coolant temperature
sensor
WA470-7 30-7
30 Testing and adjusting
General information on testing and adjusting
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
H1: Plug
-:Socket
30-8 WA470-7
30 Testing and adjusting
General information on testing and adjusting
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
W: Adapter
WA470-7 30-9
30 Testing and adjusting
Engine and cooling system
k Place the machine on a level ground and a Bucket does not move even when the bucket
lower the work equipment to the ground. lever is operated, since work equipment lock
switch is in ON (LOCK) position.
a Measure the engine speed under the following
conditions. Measuring torque converter stall speed
• Coolant temperature: 60 to 102°C 1. Start the engine.
• Hydraulic oil temperature: 45 to 55°C 2. Set transmission cut-off switch to "OFF" position
• Torque converter oil temperature: 60 to 80°C and depress left brake pedal securely.
3. Set the torque converter lockup switch (if
Testing (WA470-A000-388-K-00-A) equipped) to OFF position.
a Check the engine speed with “Monitoring/Pre- 4. Set transmission shift mode selector switch to
defined“ or “Monitoring/Custom“ function of the the MANUAL position.
machine monitor. 5. While keeping the directional lever or directional
selector switch in N (neutral) position, set the
Preparation
gearshift lever to the 4th speed.
Operate machine monitor to display “Fan 100% 6. Release parking brake.
Mode“. 7. While depressing brake pedal, set directional
a For the machine monitor operating method, see lever or directional selector switch to "F
the section of "Adjustment (Fan 100% Mode)". (forward)" or "R (reverse)" position.
a Bottom of the bucket is approx. 100 mm off a Measure the hydraulic stall speed
the ground while the bucket is level, and the respectively when the power mode and
boom angle is Max. -35.5 degrees. economy mode are selected.
4. Set work equipment lock switch to ON (LOCK)
Measuring engine speed at torque converter
position. stall and hydraulic stall (full stall)
5. Depress the accelerator pedal gradually while 1. Start the engine.
operating bucket lever tilting. Measure the 2. Set transmission cut-off switch to "OFF" position
engine speed at high idle. and depress left brake pedal securely.
3. Set the torque converter lockup switch (if
equipped) to OFF position.
30-10 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-11
30 Testing and adjusting
Engine and cooling system
a Testing tools
Sym-
Part No. Part name
bol
A 799-201-2202 Boost gauge kit
30-12 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-13
30 Testing and adjusting
Engine and cooling system
30-14 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-15
30 Testing and adjusting
Engine and cooling system
30-16 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-17
30 Testing and adjusting
Engine and cooling system
a Testing tools
Sym-
Part No. Part name
bol
1 795-502-1590 Gauge assembly
795-471-1420 Adapter
2
E 6217-71-6112 Gasket
Hose (inside diameter 14
Commercially mm, length approximately
3
available 2 m)
30-18 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-19
30 Testing and adjusting
Engine and cooling system
30-20 WA470-7
30 Testing and adjusting
Engine and cooling system
3 Clamp bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
WA470-7 30-21
30 Testing and adjusting
Engine and cooling system
a Testing tools
Sym-
Part No. Part name
bol
1 799-201-1504 Blowby checker
Plug (hose inside
2 799T-201-3210 diameter: 24 mm)
F
Cap (pipe outside
3 799T-201-3220 diameter: 25.4 mm)
30-22 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-23
30 Testing and adjusting
Engine and cooling system
a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
G 2 790-261-1204 Digital hydraulic tester
3 799-401-2320 Gauge
30-24 WA470-7
30 Testing and adjusting
Engine and cooling system
1. Open side cover (1) on the left of engine a When the EGR valve and KVGT driving oil
pressure is in the following standard range, it
is normal.
At low idle See standard value table
At high idle See standard value table
WA470-7 30-25
30 Testing and adjusting
Engine and cooling system
a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
2 790-261-1204 Digital hydraulic tester
795-790-5120 Screw
J
3 07005-01412 Gasket
790-301-1530 Elbow
4 799-401-2320 Gauge
Testing (WA470-AE20-362-K-00-A)
30-26 WA470-7
30 Testing and adjusting
Engine and cooling system
a Testing tools
Sym-
Part No. Part name
bol
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially Hose (inside diameter:
3 approximately 6 mm)
available
K Commercially Hose (inside diameter:
4 approximately 16 mm)
available
Commercially Measuring cylinder
5
available
Commercially Stopwatch
6
available
WA470-7 30-27
30 Testing and adjusting
Engine and cooling system
30-28 WA470-7
30 Testing and adjusting
Engine and cooling system
Testing (WA470-AE20-363-K-00-A)
Testing leakage from pressure limiter a Be sure to install the gasket to the both ends
1. Open engine right side cover (1) and (2). of the joint.
5. Connect test hose K3 to the end of joint K2.
a Bind the connected part of the test hose with
a wire, etc. to prevent it from coming off.
a Arrange the route of the test hose so that it
does not sag, and put its end in a container.
WA470-7 30-29
30 Testing and adjusting
Engine and cooling system
a While measuring the fuel return rate from the a Return (spill) rate from the injector is normal
injector, keep the hose on the pressure limiter if it is within the following standard value
side connected and insert the hose end in the range.
container. Engine speed Limit return (spill) rate
1. Disconnect fuel return hose (7) of return block (rpm) (cc/min)
(4).
1,600 See standard value table
a Plug the fuel hose by using a plug.
1,700 See standard value table
Plug part number: 07376-70315 1,800 See standard value table
1,900 See standard value table
2,000 See standard value table
30-30 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-31
30 Testing and adjusting
Engine and cooling system
30-32 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-33
30 Testing and adjusting
Engine and cooling system
30-34 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-35
30 Testing and adjusting
Engine and cooling system
Testing of KDPF and muffler stack for looseness and damage (WA380-A9H0-280-K-
00-A)
30-36 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-37
30 Testing and adjusting
Engine and cooling system
30-38 WA470-7
30 Testing and adjusting
Engine and cooling system
Testing (WA470-K5A0-285-K-00-A)
WA470-7 30-39
30 Testing and adjusting
Engine and cooling system
30-40 WA470-7
30 Testing and adjusting
Engine and cooling system
Testing (WA470-AKM4-923-K-00-A) 2. After loosening bolts (5) and (6), loosen locknut
1. Open side cover on the left of engine. (7).
2. Insert the starting switch key into lock (1) to 3. Alternator (8) moves to the direction (A) by
release it, and open cover (2). rotating adjustment nut (9), and tension can be
applied to alternator drive belt.
4. When the belt tension becomes appropriate,
tighten locknut (7) until it comes to contact with
boss (10).
5. Tighten bolts (5) and (6) to fix alternator (8).
Bolt (5): 28.4 to 38.2 Nm {2.9 to 3.9 kgm}
Bolt (6): 107.8 to 147 Nm {11 to 15 kgm}
6. After adjusting, install cover (3) and handrail (4),
close cover (2), and lock it with the starting
switch key.
a Check each pulley for damage, wear of the V-
groove, and the wear of the V-belt. In particular,
be sure to check that the V-belt does not touch
3. Press the belt at the intermediate point between the bottom of the V-groove.
the alternator pulley and crank pulley with your a Replace the belt with a new one if the belt is
finger and measure deflection (a). stretched and has no allowance for adjustment,
• Depressing force: Approximately 59 N {6 kg} or has slipping sound or squeaks because of
• Deflection (a): Approximately 13 to 16 mm cuts or cracks of the belt.
a If the V-belt is replaced, adjust its tension again
after one hour of operation.
WA470-7 30-41
30 Testing and adjusting
Engine and cooling system
30-42 WA470-7
30 Testing and adjusting
Engine and cooling system
Removal (WA470-A9H6-520-K-00-A)
WA470-7 30-43
30 Testing and adjusting
Engine and cooling system
Installation (HM300-A9H6-720-K-00-A)
30-44 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-45
30 Testing and adjusting
Engine and cooling system
2) Select "Connect".
• Section B: Confirm that "None" is
displayed.
30-46 WA470-7
30 Testing and adjusting
Engine and cooling system
WA470-7 30-47
30 Testing and adjusting
Engine and cooling system
30-48 WA470-7
30 Testing and adjusting
Engine and cooling system
8) Screen that appears when data writing ends 7. Turn the starting switch to the OFF position, then
successfully. "Success" is displayed on the boot the PC again (turn the starting switch to the
screen. ON position) to make sure that an error is not
• Section N: Make sure that "success" is present on the monitor.
indicated. a Failure code:
CA2765: Inj Trim Data Error
8. When replacing the injector, clear the values on
the compensation values sheet on the back of
the engine controller.
a Clear the data of the replaced injector on the
compensation values sheet that is provided
on the back of the engine controller.
a Record the data of the replaced injector in
the maintenance register.
9. When the engine controller is replaced,
inconsistency may result between the data
recorded on the sheet on the back of the engine
a Screen that appears for faulty data writing controller and that recorded in the register when
• Section P: Indicates that writing is replacement of an injector or engine controller
faulty. was done before. In such case, you must use
• If the following screen appears in the compensation character strings contained in
stead of the screen of item 8) after the the maintenance record information or import
operation of Step 7), it is suspected the compensation value information described
that the entered new data is on the top face of every injector installed on the
inappropriate. cylinders, in the same way as you did in the
(Check the data again and repeat its above when you replaced the injector.
entry.)
WA470-7 30-49
30 Testing and adjusting
Power train
Adjusting (WA470-CNA1-270-K-00-A)
30-50 WA470-7
30 Testing and adjusting
Power train
Adjusting (WA470-CNB1-270-K-00-A)
WA470-7 30-51
30 Testing and adjusting
Power train
5 Transmission case:
65 l (refill capacity)
30-52 WA470-7
30 Testing and adjusting
Power train
WA470-7 30-53
30 Testing and adjusting
Power train
30-54 WA470-7
30 Testing and adjusting
Power train
4. Remove 2nd ECMV and F or R ECMV solenoids a If the parking brake cannot be released
(2) (2 pieces), and then install plugs O as because of a failure in the electrical system,
referring to preceding position of each ECMV release the parking brake referring to
installed. "Method of releasing parking brake
• Forward travel: F solenoid and 2nd solenoid manually".
• Reverse travel: R solenoid and 2nd solenoid
k Remove the chocks.
a If a wrong solenoid is removed, the
transmission may be broken. Care must be k If the engine is started, the transmission
taken. is engaged and the machine starts
a Install the plug with its projection facing the immediately. Accordingly, when starting
ECMV. Check that the O-ring is fitted to the the engine, check the moving direction of
mating face. the machine and secure safety around the
machine thoroughly and keep depressing
a Be careful that mud or dirt will not enter the the brake pedal.
removed solenoids and valves.
k Stop the engine after moving the machine,
apply the parking brake, and chock the
wheels.
7. After finishing work, remove the testing tools and
restore the machine.
WA470-7 30-55
30 Testing and adjusting
Power train
30-56 WA470-7
30 Testing and adjusting
Power train
WA470-7 30-57
30 Testing and adjusting
Power train
• Pressure pickup plug for P1 (main relief pressure) and P2 (torque converter inlet pressure) is pressure
pickup port for torque converter valve itself. However, this machine is equipped with pressure pickup
nipple (No. 1 and 2) separately.
30-58 WA470-7
30 Testing and adjusting
Power train
WA470-7 30-59
30 Testing and adjusting
Power train
a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
2 790-261-1204 Digital hydraulic tester
N 3 799-401-2320 Gauge
799-101-5220 Nipple
4
07002-11023 O-ring
Oil pressure measuring point and measuring gauge
Measuring
gauge
No. Oil pressure to be measured
MPa {kg/
cm2}
1 Main relief pressure 6 {60}
2 Torque converter relief pressure 2.5 {25}
Torque converter outlet
3 pressure 1 {10}
4 Lockup clutch pressure 6 {60}
5 Transmission F clutch pressure 6 {60}
6 Transmission R clutch pressure 6 {60}
Transmission 1st clutch
7 pressure 6 {60}
Transmission 2nd clutch
8 pressure 6 {60}
Transmission 3rd clutch
9 pressure 6 {60}
Transmission 4th clutch
10 pressure 6 {60}
11 Lubricating pressure 1 {10}
30-60 WA470-7
30 Testing and adjusting
Power train
WA470-7 30-61
30 Testing and adjusting
Power train
a Use an oil pressure gauge of 2.5 MPa {25 kg/ a “Monitoring/Pre-defined“ (9/16) screen
cm2}.
2. Start the engine with power mode, and keep the 1. Start the engine with power mode, and keep the
directional lever or directional selector switch in directional lever or directional selector switch in
N (NEUTRAL). N (NEUTRAL).
3. While running the engine at 2,000 rpm, measure 2. While running the engine at 2,000 rpm, measure
the torque converter relief pressure (inlet the torque converter relief pressure (inlet
pressure). pressure).
a When measuring torque converter inlet pressure
accurately for troubleshooting, etc, refer "testing
with testing tools".
30-62 WA470-7
30 Testing and adjusting
Power train
WA470-7 30-63
30 Testing and adjusting
Power train
Testing lockup clutch pressure 3. Set the transmission shift mode selector switch
to AUTO.
k This measurement is done in the traveling 4. Set working mode to the power mode, start the
condition. Therefore, care must be taken to engine, and set the parking brake switch to OFF
safety of surrounding area. position.
5. Move the gear speed switch to the 3rd position.
a Lockup clutch pressure pickup port (4)
6. Set the directional lever or directional selector
switch to the F (FORWARD) or R (REVERSE),
and then start traveling.
7. While traveling with the engine speed at 2,000
rpm, measure the lockup clutch oil pressure
when the lockup pilot lamp lights up.
30-64 WA470-7
30 Testing and adjusting
Power train
Testing F (forward) clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a F (forward) clutch pressure pickup port (5)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) position while depressing the
brake pedal.
1. Remove F (forward) clutch pressure pickup port 8. After finishing test, remove the testing tools and
plug (4). Install nipple N4 and hose [1] of restore the machine.
hydraulic tester N1, and connect gauge [2] to the
hose. 3 F clutch pressure pickup port plug (4):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.
WA470-7 30-65
30 Testing and adjusting
Power train
Testing R (reverse) clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a R (reverse) clutch pressure pickup port (6)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the R (REVERSE) position while depressing the
brake pedal.
1. Remove R (reverse) clutch pressure pickup port 8. After finishing test, remove the testing tools and
plug (5). Install nipple N4 and hose [1] of restore the machine.
hydraulic tester N1, and connect gauge [2] to the
hose. 3 R clutch pressure pickup port plug
(5):
3 Nipple: 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.
30-66 WA470-7
30 Testing and adjusting
Power train
Testing 1st clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a 1st clutch pressure pickup port (7)
position.
5. While keeping the directional lever or right
directional selector switch in N (NEUTRAL), set
the gear speed switch to 1st (1st speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.
WA470-7 30-67
30 Testing and adjusting
Power train
Testing 2nd clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a 2nd clutch pressure pickup port (8)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 2nd (2nd speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.
30-68 WA470-7
30 Testing and adjusting
Power train
Testing 3rd clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a 3rd clutch pressure pickup port (9)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 3rd (3rd speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.
WA470-7 30-69
30 Testing and adjusting
Power train
Testing 4th clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a 4th clutch pressure pickup port (10)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.
30-70 WA470-7
30 Testing and adjusting
Power train
Testing lubrication pressure 3. While running the engine at 2,000 rpm, measure
the lubricating oil pressure.
a Lubrication pressure pickup port (11)
WA470-7 30-71
30 Testing and adjusting
Power train
Adjusting (WA470-C100-270-K-00-A)
Adjusting transmission main relief valve
k Stop the engine before starting adjustment
of the transmission main relief valve.
30-72 WA470-7
30 Testing and adjusting
Steering system
a Testing tools
Sym-
Part No. Part name
bol
M 79A-264-0021 Push-pull scale
Testing (WA470-CX31-384-K-00-A)
WA470-7 30-73
30 Testing and adjusting
Steering system
Measuring method
1. Start the engine.
a After starting the engine, raise the bucket
approximately 400 mm and remove the
frame lock bar.
30-74 WA470-7
30 Testing and adjusting
Steering system
WA470-7 30-75
30 Testing and adjusting
Steering system
30-76 WA470-7
30 Testing and adjusting
Steering system
WA470-7 30-77
30 Testing and adjusting
Steering system
Testing (WA470-F210-362-K-00-A)
Testing steering relief pressure
30-78 WA470-7
30 Testing and adjusting
Steering system
Testing steering pilot circuit pressure 5. After finishing the measurement, remove the
1. Remove steering control circuit hose (4) or (5) measuring tools and restore the machine.
(opposite side) of steering valve assembly (3)
through the clearance between the front side of Testing steering control circuit pressure
the operator's cab and front frame. 1. Remove steering control circuit pressure pickup
port plug (6) of steering valve assembly (3)
through the clearance between the front side of
the operator's cab and front frame.
WA470-7 30-79
30 Testing and adjusting
Steering system
30-80 WA470-7
30 Testing and adjusting
Steering system
a Before bleeding air, check that the hydraulic oil 3 Air bleeder:
level is proper. 7.8 to 9.8 Nm {0.8 to 1.0 kgm}
a If the steering valve or the steering cylinder is 4. Start the engine and run it at low idle for 5
removed and installed, bleed air from the minutes minimum.
steering circuit according to the following Bleeding air from cylinder circuit.
procedure. 1. Start engine, run engine at low idle for 5
Bleeding air (WA470-F210-231-K-00-A) minutes.
2. Run the engine at low idle, and turn the steering
Bleeding air from steering pump
wheel 4 to 5 times to the right and left.
1. Remove cover (1) located under the right side of
the hydraulic tank. a Stop the piston rod approximately 100 mm
before each stroke end and take care not to
relieve the circuit.
3. Run the engine at high idle and then, perform
the operation of Step 2.
4. Run the engine at low idle and operate the
piston rod to the end of its stroke to relieve the
circuit.
WA470-7 30-81
30 Testing and adjusting
Steering system
Testing (WA470-F5U0-365-K-00-A) 3. Stop the engine and then loosen stopper bolt (1)
until it touches the contact surface of steering
1. Align the front frame and rear frame.
stop valve (3).
2. Check that lock nut (2) on stopper bolt (1) is not
loose. a Use care not to loosen the stopper bolt
excessively. Excessive loosening can result
in pushing the spool at the tip of steering stop
valve (3) .
4. Start and run the engine at low idle, and then
return the steering wheel slowly to set the
machine to the straight travel condition. Then
stop the engine.
5. Turn stopper bolt (1) in the loosening direction
by 8.5 turns (approx. 15 mm), then fix it by lock
nut (2) .
a Adjust both the right and left sides by
following the procedure from steps 1 to 5.
3. Start the engine and turn the steering wheel to
the right and left. Check that a clearance is
maintained between the front frame stopper and
rear frame stopper.
30-82 WA470-7
30 Testing and adjusting
Brake system
WA470-7 30-83
30 Testing and adjusting
Brake system
Testing (WA380-G4C0-361-K-00-A)
30-84 WA470-7
30 Testing and adjusting
Brake system
WA470-7 30-85
30 Testing and adjusting
Brake system
30-86 WA470-7
30 Testing and adjusting
Brake system
WA470-7 30-87
30 Testing and adjusting
Brake system
30-88 WA470-7
30 Testing and adjusting
Brake system
(The adapter comes with gas charge tool a Since the pressure indication varies
ZE1.) [Inside of Japan] depending on the ambient temperature at the
• Depending on the given specification of time of measurement, you must refer to the
the nitrogen gas cylinder, nipple ZE2 is following table when measuring the gas
used for connecting the hose. pressure.
Ambient
tempera- Gas pressure
ture Remarks
°C MPa kg/cm2
15 3.37 34.4
16 3.39 34.5
17 3.40 34.6
18 3.41 34.8
19 3.42 34.9
Base gas
20 3.43 35.0 pressure
21 3.44 35.1
22 3.46 35.2
23 3.47 35.4
24 3.48 35.5
25 3.49 35.6
26 3.50 35.7
27 3.52 35.8
28 3.53 36.0
29 3.54 36.1
30 3.55 36.2
31 3.56 36.4
32 3.57 36.6
33 3.58 36.7
34 3.60 36.8
4. Turn handle (a) of gas charge tool ZE1 35 3.61 36.9
clockwise gradually and read the gauge value. 36 3.63 37.0
37 3.64 37.2
k In order to prevent damage of gas valve 38 3.65 37.3
(4), it is prohibited to rotate handle (a) 1.5 39 3.67 37.4
turns or more after the pressure of the 40 3.68 37.5
charged gas is displayed. 41 3.69 37.6
• Check that no gas leakage is recognized. 42 3.70 37.7
43 3.71 37.8
44 3.72 37.9
45 3.73 38.0
Displayed gas pressure = Base gas pressure
x ((273 + t) / (273 + 20))
(Every number in the formulas is represented
in °C.)
5. If the indicated gas pressure is below or above
the targeted level, adjust it referring to "Charging
procedure of accumulator nitrogen gas".
a A certain amount of nitrogen gas is
discharged every time measurement is done
and the pressure decreases. Be sure to
replenish by the amount of the gas
discharged.
WA470-7 30-89
30 Testing and adjusting
Brake system
30-90 WA470-7
30 Testing and adjusting
Brake system
WA470-7 30-91
30 Testing and adjusting
Brake system
(Rear side)
30-92 WA470-7
30 Testing and adjusting
Brake system
WA470-7 30-93
30 Testing and adjusting
Brake system
a Testing tools
Sym-
Part No. Part name
bol
1 793-605-1001 Brake test kit
2 790-101-1430 Coupler
3 790-101-1102 Pump
U 4 790-301-1720 Adapter
5 799-101-5160 Nipple
6 799-401-2220 Hose
7 790-261-1130 Coupling
30-94 WA470-7
30 Testing and adjusting
Brake system
WA470-7 30-95
30 Testing and adjusting
Brake system
Testing (WA470-G167-389-K-00-A)
30-96 WA470-7
30 Testing and adjusting
Brake system
k Place the machine on a level ground, lower the work equipment to the ground, set the parking
brake switch and work equipment lock switch in LOCK position, stop the engine, and chock the
wheels.
a When brake circuit equipment is removed or installed, bleed air from the brake circuit according to the
following procedure.
a Take the similar procedure for the front brake circuit and rear brake circuit. (2 places each).
a Perform air bleeding in order of right side of rear axle o left side of rear axle o right side of front axle o
left side of front axle o slack adjuster.
Bleeding air (WA470-G200-231-K-00-A)
WA470-7 30-97
30 Testing and adjusting
Brake system
30-98 WA470-7
30 Testing and adjusting
Brake system
WA470-7 30-99
30 Testing and adjusting
Brake system
a Testing conditions
• Tire inflation pressure: Specified pressure
• Road surface: Flat, dry, paved road with (11
deg. 20') grade
• Machine: Operating condition
Testing (WA380-GJ20-38E-K-00-A)
30-100 WA470-7
30 Testing and adjusting
Brake system
1. Remove side cover (1) on left of rear frame. a Measure the oil pressure at when the parking
2. Remove parking brake oil pressure pickup plug brake switch is turned OFF.
(1).
WA470-7 30-101
30 Testing and adjusting
Brake system
30-102 WA470-7
30 Testing and adjusting
Brake system
2. Loosen lock nut (3) and grip (4) of parking brake 6 Transmission case: 65 l (refill
emergency release valve (2) and open the capacity)
release valve. 2. Remove 2 bolts (1). (Right and left)
WA470-7 30-103
30 Testing and adjusting
Brake system
30-104 WA470-7
30 Testing and adjusting
Hydraulic system
WA470-7 30-105
30 Testing and adjusting
Hydraulic system
a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
R
2 790-261-1204 Digital hydraulic tester
30-106 WA470-7
30 Testing and adjusting
Hydraulic system
WA470-7 30-107
30 Testing and adjusting
Hydraulic system
a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
S 2 790-261-1204 Digital hydraulic tester
3 790-261-1130 Coupling
30-108 WA470-7
30 Testing and adjusting
Hydraulic system
WA470-7 30-109
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a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
2 790-261-1204 Digital hydraulic tester
Z
799-101-5220 Nipple
3
07002-11023 O-ring
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a Tools for testing and adjusting k When removing the inspection cover with
Sym- the boom raised, place a stand under the
Part No. Part name boom to support the boom securely.
bol
1 799-101-5002 Hydraulic tester
2 790-261-1204 Digital hydraulic tester
799-101-5220 Nipple
ZA 3
07002-11023 O-ring
Differential pressure
4 799-401-2701 gauge
a The number of each actuator in the following Testing with machine monitor
table shows the order from the top, when the Work equipment oil pressure can be measured with
control valve is seen from the front of the “Monitering/Pre-difined“ (9/16) or “Monitering“
machine. (As for the service actuator, an (monitoring code: 94700) of the machine monitor.
example of a single attachment installation is
a For the machine monitor operating method, see
shown.)
the section of "Special functions of machine
No. Actuator Valve to be relieved monitor".
1 Service Safety valve
a “Monitoring/Pre-defined“ (9/16) screen
Tilt Safety valve
3 Bucket
DUMP Main relief valve
Boom
2 (Lift cylinder) Main relief valve
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a Since the indicated value varies with the ambient a The following charging procedure is applicable
temperature, refer to the following table and to an independent accumulator as well.
check the gas pressure. 1. Remove cap (2) from the filling port of
Ambient accumulator (1).
tempera- Gas pressure 2. Loosen hexagonal socket head bolt (3)
ture Remarks
counterclockwise ( approximately 1/2 turn)
°C MPa kg/cm2 slightly by using hexagonal wrench with 6 mm
15 4.43 44.2 (SW6).
16 4.35 44.4
17 4.37 44.5
18 4.38 44.7
19 4.4 44.8
Base gas
20 4.41 45 pressure
21 4.43 45.2
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.5 45.9
27 4.52 46.1
3. Turn handle (4) of gas charge tool ZD1 fully
28 4.53 46.2 counterclockwise until it becomes immovable.
29 4.55 46.4 4. Close pressure relief valve (5).
30 4.56 46.5 5. Screw cap nut (6) into filling port of accumulator
31 4.58 46.7 (1) with hands. Adjust it so that a pressure
32 4.59 46.8 gauge (7) of gas charge tool ZD1 can be easily
33 4.61 47 seen.
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
37 4.67 47.6
38 4.68 47.8
39 4.7 47.9
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8
6. Connect gas charge tool ZD1 and nitrogen gas
Procedure for charging accumulator
cylinder according to the following procedure.
with nitrogen gas (WA470-L370-219-K-00-A)
1) Connect cap nut (7) of pressure reducing
k Loosen the oil filler cap slowly to release the valve ZD2 to the nitrogen gas cylinder.
pressure inside the hydraulic tank.
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Ambient
tempera- Gas pressure
ture Remarks
°C MPa kg/cm2
23 2.97 30.3
24 2.98 30.4
25 2.99 30.5
26 3.00 30.6
27 3.01 30.7
28 3.03 30.8
29 3.04 31.0
30 3.05 31.1
31 3.06 31.2 10.Within a week from charging nitrogen gas,
32 3.07 31.3 check that no pressure drop of nitrogen gas is
33 3.08 31.4 found.
34 3.09 31.5
a Check the brake function within 5 minutes
35 3.10 31.6
from stop of the engine. (If more than 5
36 3.11 31.7
minutes elapse from stop of the engine,
37 3.12 31.8 correct measurement becomes unavailable
38 3.13 31.9 because oil pressure in the brake circuit
39 3.14 32.0 drops.)
40 3.15 32.1 1) Place the machine on a level ground and
41 3.16 32.2 turn the parking brake switch to the “ON“
42 3.17 32.3 position.
43 3.18 32.4 2) Start and run the engine at medium speed for
44 3.19 32.5 a minute, then stop the engine.
45 3.20 32.6 3) Turn the starting switch to ON position and
7. Remove gas charge tool ZD1 from the depress the brake pedal repeatedly to record
accumulator according to the following how many times depressing are required for
procedure. the brake oil pressure caution lamp to light
up.
1) Slowly turn handle (4) clockwise, and tighten
• Number of times of depressing is less than 5:
the hexagonal socked head bolt (3).
Accumulator gas pressure may be low
2) Open pressure relief valve (5), and discharge
• Number of times of depressing is 5 or more:
nitrogen gas remaining in gas charge tool
Accumulator gas pressure is normal.
ZD1 and hose.
3) Remove gas charge tool ZD1 from the filling
port of the accumulator.
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Work equipment
Testing (WA470-LEE1-365-K-00-A)
Adjusting (WA470-LEE1-270-K-00-A)
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Work equipment
Testing (WA470-L6WR-365-K-00-A)
Adjusting (WA470-L6WR-270-K-00-A)
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The machine monitor has the ordinary functions and special functions to display the various types of
information on the LCD unit (a).
Some items are displayed automatically according to the internal setting of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The functions in this mode are displayed ordinarily. Display and setting of these functions are available
from the operator's switch operations.
(Display and setting of some functions require special operation of the switch.)
a For details of the operator mode, see Operation and Maintenance Manual.
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially. This function is used for special setting, testing, adjusting, or
troubleshooting.
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a For the displayed items, see "Structure and a The engine shutdown secondary switch is
function" or "Operation and Maintenance provided on the left wall of the front console.
Manual." This switch is used to stop the engine when it
does not stop after the starting switch is turned
to OFF position.
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a If other display is popped up by the user menu, a There are following items in the user menu.
the air conditioner adjustment screen does not • ECO Guidance
appear and operation of the air conditioner • Machine setting/information
becomes unavailable. • KDPF regeneration
• Maintenance
• Monitor setting
• Check message
[KOMTRAX message]
• There are 2 types of KOMTRAX message; one
is for the user and the other is for the technician.
• For user:
This is a user-directed message received from
the KOMTRAX base station. When this is
received, message pilot lamp is displayed on the
standard screen. Operate "Check Message" in
the user menu to read the message.
• For technician:
The standard screen does not display anything
when a message for the technician is received
from the KOMTRAX base station. Operate
“Service Message“ in the service menu to read
the message.
a For the details of user menu, see the "Operation
and Maintenance Manusl".
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Overdue replacement item screen (WA380-Q180- k If there is a thatched roof, dead leaves,
044-K-08-A) paper, or other combustibles near the
If a maintenance item that is near or exceeded the machine, set "Regeneration Disable" to
set interval, the controller displays the maintenance prevent a fire caused by the high-
caution for 30 seconds after the starting switch is temperature exhaust gas generated
turned to ON position to urge the operator to during the KDPF regeneration. For the
perform maintenance. setting procedure, see the Operation and
a The yellow caution is displayed if the remaining Maintenance Manual.
time of any item before the maintenance is 30 KDPF (Komatsu Diesel Particulate Filter) is the
hours (default value) or less, and the red caution device for capturing soot in the exhaust gas to
is displayed if the remaining time of any item is 0 clean the gas. If a certain level of soot
hour or less. accumulates on the filter, KDPF automatically
a You can check the maintenance information by starts the purification treatment of burning the
pressing the menu switch while guidance icon trapped soot in order to maintain the
(a) is displayed. performance of its filter in good condition. This
purification treatment is called "regeneration."
a To reset the remaining time left after finishing the If an operation that may lower the filtering
maintenance, further operations are required at performance of the KDPF continues for a long
the User menu. period of time, the regeneration may be
a Perform setting and changing of the performed to protect the KDPF system,
maintenance function at the service menu. regardless the amount of the accumulated soot.
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a Although “KDPF Regeneration“ is normally If you stop the machine, KDPF Regeneration
performed automatically, it may not be able screen appears once for every 2 hours after
to burn soot as intended or improve the the occurrence. If you do not perform “KDPF
purifying performance sufficiently depending Regeneration“, the display is replaced with
on the operating conditions. In such case, the standard screen in 30 seconds.
the KDPF soot accumulation caution lamp
(2) lights up. If the lamp lights up, stop the
machine at a safe place and perform the
manual stationary regeneration. For details
of the procedure, see the Operation and
Maintenance Manual.
2. Manual stationary regeneration
There are 2 levels of monitor displays to require
the manual stationary regeneration, depending
on the degree of emergency.
The action level caution lamp goes out in 2 After the machine is stopped, the screen
seconds and the following standard screen changes to “KDPF Regeneration“ screen in 3
appears. seconds. Then “KDPF Regeneration“ screen
and standard screen with the caution lamp lit
are alternately displayed until the manual
stationary regeneration is performed.
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a The engine maximum output and a The entire LCD is not turned to white when the
maximum speed are limited to protect the engine is running.
engine and KDPF system.
a If there is a display error in the LCD, only that
a The manual stationary regeneration ends part is indicated in black.
when the soot accumulation is reduced to
a If you press any of Up switch (A), Down switch
2 g/l maximum and approximately 35
(B), Return switch (C), Enter switch (D) and
minutes (the time varies depending of the
Menu switch (E), the display is returned to the
soot accumulation reduced in the
original screen.
regeneration) has elapsed from the start
of the regeneration. Reference: On the LCD panel sometimes, there
may be black spots (spots not lit) and bright spots
k If the work is continued without (remaining constantly lit) as one of its
performing the manual stationary characteristics.
regeneration and the soot quantity If the number of the bright spots and black spots
exceeds the allowable limit, action does not exceed 10, the LCD panel is not faulty or
level "L04" lights up and the repair of defective.
the machine will be required.
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3. After the "Usage Limitation Setting" screen is password with the numeral input switches (E)
displayed, select a desired setting by using the and validate it with the function switch.
function switch. Return switch (C): Deletes input numbers/
Up switch (A): Moves your selection to the Returns the display to the previous screen
immediate above item Enter switch (D): Validates the entered
Down switch (B): Moves selection to the below password
item
a Default password: [000000]
Return switch (C): Cancels selection and returns
the display to the previous screen a When the input password is correct, the
Enter switch (D): Validates the selection screen changes to the next screen.
a When the input password is incorrect, the
message to request inputting the password
again is displayed.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it
is not accepted).
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Monitoring/ Pre-defined screen (6/16) Engine intake and exhaust pressure system
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 37400 Ambient Pressure kPa ENG
3 36500 Charge Pressure-A kPa ENG
4 48100 Turbo Speed r/min ENG
5 48200 Mass Air Flow kg/min ENG
Monitoring/ Pre-defined screen (7/16) Engine post-treatment system
Applicable
No. ID Monitoring item Unit (SI)
component
1 47000 KDPF Outlet Pressure kPa KDPF
2 47100 KDPF Delta Pressure kPa KDPF
3 47200 KDPF 1 Outlet Temperature °C KDPF
4 47300 KDOC 1 Inlet Temperature °C KDPF
5 47400 KDOC 1 Outlet Temperature °C KDPF
6 47600 Dosing Fuel Pressure kPa KDPF
Monitoring/ Pre-defined screen (8/16) Engine
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 37200 Engine Oil Pressure kPa ENG
3 48400 Crankcase Pressure kPa ENG
4 47300 KDOC 1 Inlet Temperature °C KDPF
5 36500 Charge Pressure-A kPa ENG
6 48100 Turbo Speed r/min ENG
Monitoring/ Pre-defined screen (9/16) Work equipment, power train hydraulic system
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 32601 T/C Input Oil Pressure MPa T/M
3 32603 T/C Output Oil Pressure MPa T/M
4 95302 Steering Pump Pressure MPa BBC
5 94700 Loader Pump Pressure MPa BBC
Monitoring/ Pre-defined screen (10/16) Transmission clutch operation system
Applicable
No. ID Monitoring item Unit (SI)
component
1 41802 Fill Time (1st) msec T/M
2 41803 Fill Time (2nd) msec T/M
3 41804 Fill Time (3rd) msec T/M
4 41805 Fill Time (4th) msec T/M
5 41806 Fill Time (Reverse) msec T/M
6 41808 Fill Time (Forward) msec T/M
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a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
KDPF: The engine controller is in charge of detecting the monitoring information.
T/M: The transmission controller is in charge of detecting the monitoring information.
BBC: The work equipment controller is in charge of detecting the monitoring information.
MON: The monitor controller is in charge of detecting the monitoring information.
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a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
KDPF: The engine controller is in charge of detecting the monitoring information.
T/M: The transmission controller is in charge of detecting the monitoring information.
BBC: The work equipment controller is in charge of detecting the monitoring information.
MON: The monitor controller is in charge of detecting the monitoring information.
Note 1: “Fuel Rate“ (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it is a theoretical value,
it is slightly different from the actual fuel consumption ratio).
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Abnormality record (mechanical a If you enter a 2-digit item number with the
systems) (WA380-Q1S2-100-K-00-A) numeral input switches (E), the entered item
The machine monitor logs the past and currently is directly selected.
occurring failures classifying them into the
mechanical system abnormality and electrical
system abnormality.
To check the mechanical system abnormality record,
perform the following procedures.
a For the failure code list, see "40 Failure code list
for troubleshooting".
1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" screen.
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a If the number of occurrence is 1 (first Down switch (B): Moves the selection down by
occurrence), the service meter reading at the one item
first occurrence and that at the last Return switch (C): Returns to the “Service Menu“
occurrence are the same. screen
Enter switch (D): Validates the selection
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or correction a If you enter a 2 digit item number with the
of it is not confirmed. numeral input switches (F), the entered item
is directly selected.
a An abnormality record of the mechanical
system cannot be deleted.
a For all of the failure codes that the machine
monitor can record, see the failure code list.
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a On the electrical systems abnormality record a The screen is in the clear mode if graphic
screen, up to 20 cases currently stored are mark [CLEAR] is indicated at the bottom
displayed. of the screen.
If the number of abnormality records Up switch (A): Moves your selection to
increases to 21 or beyond, the latest the item right above the current one
occurrence code is displayed and the oldest (when 2 or more abnormalities are
one is deleted. recorded)
a If the number of occurrence is 1 (first Down switch (B): Moves your selection to
occurrence), the time of the first occurrence the item right below the current one
is identical with the time being read on the (when 2 or more abnormalities are
service meter at the first occurrence. recorded)
Return switch (C): Returns to
a If [E] is displayed on the left of a failure code,
“Abnormality Record“ screen
the abnormality is still occurring or correction
of it is not confirmed. Enter switch (D): Clears the information
one by one
a For all of the failure codes that the machine
Menu switch (E): Clears all information at
monitor can record, see the failure code list.
once
a When clearing the information one by
one: Select the item to be cleared by
using Up switch (A) or Down switch (B)
and press the enter switch (D) to clear it.
a When clearing all the information at once:
Press menu switch (E) to clear all the
items regardless of the selection of the
individual item.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the item is not cleared.
4. Clearing abnormality record
1) While “Electrical Systems“ screen is
displayed, perform the following operation.
Switch operation: While pressing Down
switch (B), press numeral input switches (F)
in the sequence of "1"o"2"o"3".
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a The following figure shows the screen 2. Selecting maintenance record item
when an individual item is cleared (it is After the “Maintenance Record“ screen is
slightly different from the screen when all displayed, select the item to confirm.
the item are cleared at once). Up switch (A): Moves the selection up by one
item
Down switch (B): Moves the selection down by
one item
Return switch (C): Returns the display to the
“Service Menu“ screen
Enter switch (D): Validates the selection
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No. Maintenance record items Enter switch (D): Validates the selection
48 KDPF Filter Cleaning
52 Fuel Doser Cleaning
3. Information displayed in “Maintenance Record“
screen
The following information is displayed.
(a): Maintenance items
(b): Number of replacements up to now
(c): Service meter reading (SMR) at the last
replacement
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a Setting for the following items is available in a Even if ON/OFF of each item has been set, if
"Maintenance Mode Setting". the above setting is changed, it overrides the
Maintenance Mode Setting item individual setting.
No.
Maintenance Mode a The maintenance function for cleaning KCCV
On/Off filter, KDPF filter and fuel doser remains
"Maintenance Mode
00 Maintenance enabled even if "OFF" is selected.
Change"
Notice Time
Setting
"Air Cleaner OFF/ON Set
49 Cleaning / Change
Interval" Set Value
"Fuel Pre Filter OFF/ON Set
41 Change Interval" Set Value
"Engine Oil Change OFF/ON Set
01
Interval" Set Value
"Engine Oil Filter OFF/ON Set
02 Change Interval" Set Value
"Transmission Oil OFF/ON Set
13 Filter Change
Interval" Set Value
4. Description of maintenance mode change
"Fuel Main Filter OFF/ON Set procedure (Maintenance Notice Time Setting)
03 Change Interval" Set Value Select "Maintenance Notice Time Setting" of
"Transmission Oil ON/OFF Set "Maintenance Mode Change" and proceed to its
12 Change Interval" Set Value setting.
"Axle Oil Change OFF/ON Set
15
Interval" Set Value
"Hydraulic Oil OFF/ON Set
10 Change Interval" Set Value
"Hydraulic Oil Filter OFF/ON Set
04 Change Interval" Set Value
"Hydraulic Oil Tank OFF/ON Set
05 Breather Change
Interval" Set Value
99 Returns all to Default Values
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Return switch (C): Returns the display to Menu switch (E): Clears all the input phone
"Maintenance Mode Setting" screen numbers.
Enter switch (D): Executes initialization Numeral input switch (F): Inputs the phone
number.
a The initialization work is completed if the
Initialization Completion screen appears
sometime after pressing Enter switch (D)
being followed by the Maintenance Mode
Setting screen.
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Default Default
Item name setting Remarks Item name setting Remarks
• If high lift boom Komatsu
Select "ADD" and do not
(optional) is used , Smart ADD change it.
select "High Lift". Loader Logic
Select "ADD" when Auto Idle Select "ADD" on machines
Auto Grease NO ADD optional equipment is Stop Setting NO ADD for North America.
installed. 2) Setting of work equipment control
Battery Select "NO ADD" and do Select “Work Equipment Control“ and set
Electrolyte NO ADD not change it.
Level Sensor one of TYPE A to G.
If difference is recognized Up switch (A): Moves the selection up by one
in the travel speed display, item
Tire Size adjust it with this function. Down switch (B): Moves the selection down
Compensa- 0% Increasing the setting by by one item
tion 1% increases the travel Return switch (C): Cancels the selection and
speed by 1% against the returns the display to “Option Select“ screen
one at 0%. Enter switch (D): Validates the setting and
Tire Type Select "B" when 26.5 tires returns the display to “Option Select“ screen
A
are installed.
Emergency Select "ADD" when
Steering ADD optional equipment is
installed.
When the multi-function
lever (joystick lever is not
installed) or directional
J/S or FNR (FNR) switch (on the right)
NON
SW is installed, select "OPT
FNR". When the joystick
steering is installed, select
"J/S FNR".
Select "ADD" and do not
Lift Up Mode ADD change it.
Select "ADD" and do not
ECSS ADD change it.
Select "ADD" and do not
T/C Lockup NO ADD
change it.
Prohibition of
Select "NO ADD" and do
use of 4th NO ADD not change it.
speed
Set as follows according to
installed optional
equipment and
destination.
• Set to "HEATER" if
machine is equipped
with optional
Tow Stage equipment and used in • TYPE A
NO ADD Japan.
Low Idle Main Valve Type: 2 spool
• Set to "KOHAG" if
Lever Type: 2 levers
machine is equipped
with optional • TYPE B
equipment and used Main Valve Type: 2 spool
outside Japan. Lever Type: MF lever
• Select "NON" when • TYPE C
optional equipment is Main Valve Type: 3 spool
not installed. Lever Type: 3 levers
F1 PWR Select "ADD" and do not • TYPE D
ADD change it.
CUT Main Valve Type: 3 spool
Lever Type: MF lever + PCS
• TYPE E
Non Use
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• TYPE F
Non Use
• TYPE G
Non Use
a Depending on the set type of the work
equipment control, the following optional
equipment selections will be fixed and
unchangeable.
• Semi-auto Digging
• Boom specification
3) Setting tire size compensation
Select and set “Tire Size Compensation“.
Up switch (A): Increases the set value by 1% 4. Reflecting setting
Down switch (B): Decreases the set value by If you exit “Option Select“ screen by using the
1% return switch after completing the setting of the
Return switch (C): Cancels the setting items, a screen appears to urge you to turn the
operation before validation and returns the starting switch to OFF position. Turn the starting
display to “Option Select“ screen switch to OFF position once and “Option Select“
Enter switch (D): Validates the setting and is completed.
returns the display to “Option Select“ screen
a When you do not press the enter switch (no
change is made) even once for any item,
even if you exit “Option Select“ screen, this
screen does not appear.
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3. Selecting unit
After “Unit“ screen is displayed, select the unit to
be set.
Up switch (A): Moves the selection up by one
item
Down switch (B): Moves the selection down by
one item
Return switch (C): Cancels the selection and
returns the display to “Default“ screen
Enter switch (D): Validates the setting and
returns the display to “Default“ screen
2. Selecting sub menu
Select “Rear View Monitor Setting“ on “Default“
screen.
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[Reference]
• If a normally operating cylinder is cut out, the
following phenomena occur.
1) Decrease in engine speed
2) The quantity of final injection rate 3. Setting regeneration for service
command increases. When “Regeneration for Service“ screen is
• If the engine is running at around high idle, displayed, the following informations are
however, the engine speed may not displayed corresponding to the KDPF
decrease because for the reason of engine regeneration condition. Set the KDPF
control. regeneration according to the given messages.
• In this case, lower the engine speed by (a): Soot accumulation level
adjusting the accelerator pedal depressing, (b): Regenerating condition of KDPF
and make the judgment observing increase (c): Selectable items
of the final fuel injection volume command. (d): Message
30-178 WA470-7
30 Testing and adjusting
Electrical system
1) KDPF active regeneration (manual stationary a The active regeneration for service
regeneration) automatically stops in 40 minutes.
Select “Manual Stationary Regeneration“ on However, if the regeneration is started
“Regeneration for Service“ screen. with the soot accumulation of
Return switch (C): Returns the display to approximately 4 g/liter and if the soot
“Diagnostic Tests“ screen accumulation still remains at above 2 g/
Enter switch (D): Executes “Manual liter after 40 minutes from the start, the
Stationary Regeneration“ regeneration is continued until the soot
accumulation decreases to 1.99 g/liter.
a The screen displays “Monitoring
Selection Menu“ screen by the following
switch operations while the regeneration
for service is in progress.
• Switch operation: While pressing
Down switch (B), press numeral input
switches (E) "1" o "2" o "3" in order.
To return the regeneration for service
screen from monitoring screen, press
the return switch (C).
a For the monitoring operating, see
"Monitoring" of "Ordinary functions and
special functions of machine monitor".
2) Finishing regeneration
When “Regeneration for Service“ is
completed, “Regeneration completed“ is
displayed on the screen.
WA470-7 30-179
30 Testing and adjusting
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30-180 WA470-7
30 Testing and adjusting
Electrical system
Adjusting (WA500-Q170-270-K-00-A)
The machine monitor implements the initial setting
after disassembly or replacement of the
transmission or hydraulic components, to
compensate installation errors or manufacturing
variations of individual parts. 2. Move to the tab of T/M by using menu switch (E)
and select T/M Oil Temperature.
a Adjusting function
No. Adjustment item
1 ECMV Automatic Compensation
2 T/M Initial Learning
3 T/M Initial Learning Reset
4 T/M Shift Point
5 T/M Shift Point Data Clear
6 Boom Angle Sensor for EPC (Raise)
7 Boom Angle Sensor for EPC (Lower)
8 Boom Raise Adjustment
9 Boom Lower Adjustment
10 Bucket Tilt Adjustment
11 Bucket Dump Adjustment
12 3rd Ext Adjustment *1
13 3rd Ret Adjustment *1
14 J/S Right Adjustment *1
15 J/S Left adjustment *1
16 PCS Adjustment(Push) *1
17 PCS Adjustment(Pull) *1
18 Change of Boom Lever Pattern
19 Change of Bucket Lever Pattern
20 Boom Stop Modulation
21 2-Stage Low Idle Throttle Position
22 Steering Pump Displacement *1
23 Steering Pump Displacement *1
Fan Reverse Cycle Checking transmission oil pressure control
24
1. Start the engine, depress the brake pedal fully
25 Fan Reverse Duration and then, release the parking brake.
26 ECSS Operating Speed 2. Set the transmission shift mode to "Manual", and
27 Fan 100% Mode move the directional lever to F (FORWARD),
(*1): These items are not used.
WA470-7 30-181
30 Testing and adjusting
Electrical system
and set the gear speed switch to 4th (4th • Parking brake switch: ON
speed). • Directional lever: N position
3. Referring to "Preparation for transmission ECMV • Engine: Low idle
current adjustment", check that the transmission • Accelerator pedal: Released
oil temperature is within the range from 55 to 70° 1. Selecting menu screen
C. If the temperature is not within the range 55 to Select “Adjustment“ on “Service Menu“ screen.
70°C, perform torque converter stall operation to
adjust the oil temperature to 55 to 70 °C.
4. Return the directional lever to "N" (Neutral),
leave the machine for 3 minutes, and check that
the oil temperature remains within the range 55
to 70 °C.
5. Operate the directional lever and gear speed
switch as shown in the following table to
circulate the oil around inside of the
transmission.
Order 1 2 3 4
Gear
speed N2 F2 F1 F2
Holding Min. 2 Min. 2 Min. 2 Min. 2 2. Selecting sub menu
time seconds seconds seconds seconds
After the “Adjustment“ screen is displayed,
Order 5 6 7 8 select “ECMV Automatic Compensation“.
Gear
speed F3 F4 F3 F2
Holding Min. 2 Min. 2 Min. 2 Min. 2
time seconds seconds seconds seconds
Order 9 10 11
Gear
speed N2 R2 N2
Holding Min. 2 Min. 2 Min. 2
time seconds seconds seconds
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30 Testing and adjusting
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WA470-7 30-183
30 Testing and adjusting
Electrical system
k Be sure to perform the learning work in a 4. Operate the directional (FNR) lever and gear
place where an ample traveling area is speed switch according to the following table to
available while paying attention to safety in perform the initial learning.
the surrounding area.
a When setting N2 for the first time, shift
1. Selecting menu screen directional lever to N position after setting
Select “Adjustment“ on “Service Menu“ screen. gearshift switch to F2 or R2.
(Since gear speed is not changed if gearshift
switch is set to 2 after shifting directional
lever to N position, set gearshift switch to 2
first, and then shift directional lever to N
position.
If directional lever is shifted to N position
while gearshift switch is set at other than 2,
operate directional lever to F position or R
position once. Then operate directional lever
to N position after setting gearshift switch to
F2 or R2.)
Order 1 2 3 4
Gear
2. Selecting sub menu speed N2 F2 F1 F2
After the “Adjustment“ screen is displayed, Holding Min. 5 Min. 5 Min. 5 Min. 3
select “T/M Initial Learning“. time seconds seconds seconds seconds
Order 5 6 7 8
Gear
speed F3 F4 F3 F2
Holding Min. 3 Min. 3 Min. 3 Min. 3
time seconds seconds seconds seconds
Order 9 10 11
Gear
speed N2 R2 N2
Holding Min. 3 Min. 3 Min. 3
time seconds seconds seconds
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30 Testing and adjusting
Electrical system
WA470-7 30-185
30 Testing and adjusting
Electrical system
30-186 WA470-7
30 Testing and adjusting
Electrical system
4. The input value is displayed at the right part of 2. Selecting sub menu
the screen. If this value is correct, press the After the “Adjustment“ screen is displayed,
enter switch (D) again. select “T/M Shift Point Data Clear“.
5. When the input numeric value is displayed in the 3. When “T/M Shift Point Data Clear“ screen is
left display area, the setting is complete. displayed, press enter switch (D).
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.
WA470-7 30-187
30 Testing and adjusting
Electrical system
30-188 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-189
30 Testing and adjusting
Electrical system
30-190 WA470-7
30 Testing and adjusting
Electrical system
a Do not move the lever to RAISE detent a If the return switch is pressed while the
position. calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.
WA470-7 30-191
30 Testing and adjusting
Electrical system
lever at the current position. While holding the Correcting the position just before the boom
lever at that position, press enter switch (D). lever LOWER detent
a Perform this adjustment with the engine stopped
after the bucket is lowered to the ground.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.
30-192 WA470-7
30 Testing and adjusting
Electrical system
4. When "1" is displayed in the display area, this 2. Selecting sub menu
adjustment is complete. After the “Adjustment“ screen is displayed,
select “Boom Lower Adjustment“.
WA470-7 30-193
30 Testing and adjusting
Electrical system
30-194 WA470-7
30 Testing and adjusting
Electrical system
a Do not set the lever to the bucket TILT detent a If the return switch is pressed while the
position. calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.
WA470-7 30-195
30 Testing and adjusting
Electrical system
5. Return the lever finely. When the boom stops Adjustment (Bucket Dump
moving (front wheels are off ground), hold the Adjustment) (WA380-CN25-270-K-00-A)
lever at the current position. While holding the a This function is used to perform calibration in
lever at that position, press enter switch (D). order to correct dispersion of the starting current
of the bucket DUMP lever.
a Perform this adjustment with the engine running.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.
30-196 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-197
30 Testing and adjusting
Electrical system
a This function is used to modify the fine-controllability and response of the boom by changing the data on
EPC output current to the boom lever stroke.
a Characteristics of tables 0 to 4 are summarized as shown in the table below. (table when shipped: 2)
a Normally, change is made to tables No. 1 to No. 3. When selecting No. 0 or No. 4 table, thorough
preliminary performance check and operator evaluation are required.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.
30-198 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-199
30 Testing and adjusting
Electrical system
30-200 WA470-7
30 Testing and adjusting
Electrical system
a This function is used to modify the fine-controllability, response and shock dump of the bucket by changing
the data on EPC output current to the bucket lever stroke.
a Characteristics of tables 0 to 2 are summarized as shown in the table below. (table when shipped: 1)
WA470-7 30-201
30 Testing and adjusting
Electrical system
30-202 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-203
30 Testing and adjusting
Electrical system
30-204 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-205
30 Testing and adjusting
Electrical system
30-206 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-207
30 Testing and adjusting
Electrical system
30-208 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-209
30 Testing and adjusting
Electrical system
5. When the input numeric value is displayed in the 2. Selecting sub menu
left display area, the setting is complete. After the “Adjustment“ screen is displayed,
select “Fan 100% Mode“.
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.
30-210 WA470-7
30 Testing and adjusting
Electrical system
No Injection (HM300-AD00-25L-K-00-A)
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
machine monitor has a function to crank the engine
without injecting fuel to lubricate the engine before 3. Starting no-injection cranking
starting it. If No Injection cranking (no fuel injection to every
cylinder) is enabled, a message to notify that is
Set the no-injection cranking while the engine is
displayed on the screen. Under this condition,
stopped.
turn the starting switch to the START position
1. Selecting menu and crank the engine.
Select “No Injection“ on “Service Menu“ screen.
a While the screen is changing to the following
screen, the screen of “Getting Ready.“ is
displayed.
a Do not crank the engine for 20 seconds or
longer to protect the starting motor.
WA470-7 30-211
30 Testing and adjusting
Electrical system
a When you want to turn the starting switch to Select “KOMTRAX Settings“ on “Service Menu“
ON position again, set a sufficient time (1 screen.
minute minimum) before doing so.
5. Prohibiting no-injection cranking
Even if the operator tries to perform the No
Injection cranking while the engine is running,
the message "The engine is operating" is
displayed and the no-injection cranking does not
become effective.
a This function can be selected even when the
engine is running. However, if you execute
the no-injection cranking, a message “Please
turn the key off once.“ appears on the
screen.
30-212 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-213
30 Testing and adjusting
Electrical system
30-214 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-215
30 Testing and adjusting
Electrical system
Adjusting (WA380-Q162-270-K-01-A)
30-216 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-217
30 Testing and adjusting
Electrical system
30-218 WA470-7
30 Testing and adjusting
Electrical system
WA470-7 30-219
30 Testing and adjusting
Pm clinic
Pm clinic (ALL-2160-001-A-00-A)
30-220 WA470-7
30 Testing and adjusting
Pm clinic
WA470-7 30-221
30 Testing and adjusting
Pm clinic
2. Transmission valve
a When shifting transmission gear to forward or reverse, apply brake securely.
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
2.12 to 2.52 2.12 to 2.52
Low idle
{21.5 to 25.5} {21.5 to 25.5}
Main relief
pressure Engine 2.35 to 2.75 2.35 to 2.75
speed: • Torque
2,000 rpm converter oil {24.0 to 28.0} {24.0 to 28.0}
Torque tempera-
converter Engine ture: 60 to
0.1 to 0.88 0.1 to 0.88
inlet speed: 80°C
pressure 2,000 rpm • {1.0 to 9.0} {1.0 to 9.0}
(*1) Transmis-
Torque sion:
converter Engine Neutral
0.06 to 0.71 0.06 to 0.71
outlet speed:
pressure 2,000 rpm {0.6 to 0.7} {0.6 to 0.7}
(*1)
MPa
2.2 to 2.5 2.2 to 2.5
1st {kg/cm2}
{22.5 to 25.5} {22.5 to 25.5}
2.2 to 2.5 2.2 to 2.5
2nd • Torque
converter oil {22.5 to 25.5} {22.5 to 25.5}
tempera- 2.15 to 2.45 2.15 to 2.45
3rd
ECMV ture: 60 to {22 to 25} {22 to 55}
output 80°C 2.15 to 2.45 2.15 to 2.45
4th • Engine
(clutch) speed: {22 to 25} {22 to 25}
pressure 2,000 rpm 1.91 to 2.21 1.91 to 2.21
F (forward)
Manual {19.5 to 22.5} {19.5 to 22.5}
switch at 1.91 to 2.21 1.91 to 2.21
R (reverse) ON
{19.5 to 22.5} {19.5 to 22.5}
L/C 1.51 to 1.81 1.51 to 1.81
(lockup) {15.5 to 18.5} {15.5 to 18.5}
*1: Items which can be inspected in special functions of machine monitor
3. Steering
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
Secure frame with frame lock bar.
• Hydraulic oil temperature:
Steering 23.3 to 25.7
45 to 55°C MPa 22.0 to 25.7
relief
• Engine speed: High idle {237.5 to
pressure {kg/cm2} {225 to 262.5}
• Maximum pressure at 262.5}
(*1)
operation
*1: Items which can be inspected in special functions of machine monitor
30-222 WA470-7
30 Testing and adjusting
Pm clinic
4. Brake
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
Torque converter oil
Parking temperature: 60 to 80°C MPa Min. 2.32 Min. 2.32
brake inlet
Engine speed: Low idle {kg/cm } {Min. 23.5}
2 {Min. 23.5}
pressure
As parking brake is released
Tire inflation pressure:
Specified pressure
Parking
Flat paved road with a slope of
brake — Stopped Stopped
1/5 (11 degrees 20 minutes)
perfor-
and dry surface
mance
Set machine in operating
condition.
Parking
brake disc mm 3.12 to 3.28 2.97
thickness
Charge 5.9 to 6.4 5.4 to 6.88
cut-in
Hydraulic oil temperature: 45 (60 to 65) {55 to 70}
pressure
to 55°C
Charge 9.8 to 10.78 9.4 to 11.3
Engine speed: Low idle
cut-out
pressure {100 to 110} {95 to 115}
Hydraulic oil temperature: 45 MPa
Brake oil to 55°C 4.4 to 5.2 Min. 4.2
pressure {kg/cm 2}
{44.8 to 53} {Min. 42.7}
Engine speed: Low idle
Engine stopped
Drop of Measure lowering of oil Max. 0.49 Max. 0.49
brake oil pressure from 4.9 MPa {50 kg/
pressure cm2} after depressing brake {Max. 5} {Max. 5}
pedal for 5 min.
Tire inflation pressure:
Specified pressure
Test on flat, level, straight, and
dry paved road.
Wheel Travel speed at beginning of
brake brake application 20 km/h:
Delay in applying brakes Max. m Max. 5 Max. 5
perfor-
mance 0.1sec.
Brake pedal depressing force:
Specified depressing effort 293
to 353Nm {29.9 to 35.9 kg}
Measure braking distance.
Use disc wear indicator for Shaft
Wear of measurement. Protrusion of protrusion
wheel Oil pressure: 4.9 MPa {50 kg/ mm shaft reaches wear
brake disc cm }2 limit position
Pedal depressed completely 0 [Max. 2.4]
WA470-7 30-223
30 Testing and adjusting
Pm clinic
5. Work equipment
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
Work
equipment 32.5 to 36.1 29.9 to 36.1
relief Bucket relief
pressure {332 to 368} {305 to 368}
(*1) MPa
Work Power mode {kg/cm2}
equipment Boom control 1.27 to 1.47 1.17 to 1.57
valve LS Hydraulic oil
lever: Half
differential temperature: {13 to 15} {12 to 16}
stroke
pressure 45 to 55°C
Boom Engine speed: Raising time 5.4 to 6.4 Max. 7.7
speed High idle
Lowering time 2.6 to 3.6 Max. 4.4
Bucket full
Bucket tilt sec 2.1 to 2.7 Max. 3.2
stroke time
back Level o apply
speed a load 1.2 to 1.8 Max. 2.0
afterward
Hydraulic oil Retraction of
Hydraulic temperature: lift cylinder rod Max. 30 Max. 36
drift in 45 to 55°C mm/15
Retraction of
work min.
bucket Max. 20 Max. 24
equipment Engine
stopped cylinder rod
*1: Items which can be inspected in special functions of machine monitor
6. Hydraulic fan
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
• Engine speed: High idle
• Coolant temperature: Min.
Cooling 95°C
fan • Hydraulic oil temperature:
Min. 50°C 1,200 to 1,400 1,100 to 1,500
maximum
speed (*1) • Torque converter oil
temperature: Min. 105°C
• Can be substituted with fan
100% mode rpm
• Engine low idle
• Coolant temperature: Max.
Cooling 70°C
fan • Hydraulic oil temperature:
minimum 125 to 225 75 to 275
Max. 70°C
speed (*1) • Torque converter oil
temperature: Max. 88°C
• Air conditioner: OFF
• Engine speed: High idle
Cooling 12.9 to 15.7 12.2 to 16.4
• Hydraulic oil temperature:
fan drive
50°C {131 to 161} {124 to 168}
pressure
• Fan 100% mode (*2)
Cooling MPa
• Fan rotating in reverse
fan {kg/cm2}
• Engine: High idle 2.16 to 2.86 1.98 to 3.04
reverse
• Hydraulic oil temperature:
solenoid {22.0 to 29.2} {20.2 to 31.0}
50°C
output
• Fan 100% mode (*2)
pressure
*1: Items which can be inspected in special functions of machine monitor
*2: For the fan 100% mode, see "Testing and adjusting", "Special functions of machine monitor".
30-224 WA470-7
30 Testing and adjusting
Pm clinic
7. Axle
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
Draining of Front axle
differential
Must be no excessive metal
Visual —
Rear axle particles
check of
plug
MEMO
WA470-7 30-225
30 Testing and adjusting
Pm clinic
30-226 WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model Serial Number
40 Troubleshooting
6 40 Troubleshooting
WA470-7 40-1
40 Troubleshooting
Table of contents
40-2 WA470-7
40 Troubleshooting
Table of contents
WA470-7 40-3
40 Troubleshooting
Table of contents
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
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
40-4 WA470-7
40 Troubleshooting
Table of contents
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
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
WA470-7 40-5
40 Troubleshooting
Table of contents
40-6 WA470-7
40 Troubleshooting
Table of contents
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
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
WA470-7 40-7
40 Troubleshooting
Table of contents
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
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
40-8 WA470-7
40 Troubleshooting
Table of contents
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
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
WA470-7 40-9
40 Troubleshooting
Table of contents
40-10 WA470-7
40 Troubleshooting
General information on troubleshooting
(Rev. 2011/09)
k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.
k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k Ifthe radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.
k When removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1)Is there any sign of irregularities of the machine?
2)Make checks before starting day's work.
3)Make checks of other items.
4)Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the
method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of
the failure, then use the troubleshooting flowchart to locate the failure exactly.
WA470-7 40-11
40 Troubleshooting
General information on troubleshooting
40-12 WA470-7
40 Troubleshooting
General information on troubleshooting
(Rev. 2011. 7)
WA470-7 40-13
40 Troubleshooting
General information on troubleshooting
40-14 WA470-7
40 Troubleshooting
General information on troubleshooting
2
3 Check of hydraulic oil level Between H and L Refilling of oil
4 Check of hydraulic oil strainer ― Clean or replace
5 Check of hydraulic oil filter ― Replace
6 Check of transmission case oil level Between H and L Refilling of oil
7 Check of axle case oil level (front and rear) Between H and L Refilling of oil
Retighten or
1 Check of battery terminal for looseness and corrosion ―
replace
Retighten or
2 Check of alternator terminal for looseness and corrosion ―
replace
Check of starting motor terminal for looseness and Retighten or
3 ―
corrosion replace
c: Electrical equipment
Charge or
4 Check of battery voltage (with engine stopped) 20 to 30 V replace
5 Check of battery electrolyte level Between H and L Add or replace
Check of wiring harness for discoloration, burnt areas and
6 cover peeling ― Repair or replace
Check for coming off of wiring harness clamp and sagging
7 of wiring harness ― Repair
8 Check of grounding ― Repair
9 Check for loose connector and damaged lock ― Repair or replace
Check of connector pin for corrosion, bends and ― Repair or replace
10
deformation
Dry, clean or
11 Check of connector for water and foreign material ― replace
WA470-7 40-15
40 Troubleshooting
General information on troubleshooting
40-16 WA470-7
40 Troubleshooting
General information on troubleshooting
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Accumulated combustibles around hot engine parts such as the engine, KDPF, and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
failures.
a a1 and a2, —, b1, b2, — refer to the symbols in the table on the previous page.
a1. and b1. Check for unusual noise and smell Check and remove any accumulated dirt and
Check for unusual noise and smell. combustibles (dead leaves, twigs, etc.) around the
battery.
Some causes of unusual noise and smell can
damage the machine if they are left as they are. c16. Check and cleaning of rear view camera
Therefore, stop the machine immediately when you Check the rear view camera for any defect, and
find any abnormality. repair any failures.
a2. Check around engine and dirt removal d1. Check of undercarriage (track, sprocket,
Check and remove any accumulated dirt around the idler and guard) for abnormalities, wear, loose
engine and any combustibles (dead leaves, twigs, bolts and oil leakage from roller
etc.) on hot engine parts such as the engine, KDPF, Repair any abnormalities.
turbocharger, etc. d2. Check of handrails and steps for
a3. Check for water leakage around engine abnormalities and loose bolts
a4. Check for oil leakage around engine Repair any abnormalities and retighten any loose
Check any oil leaks from the engine and any water bolts.
leaks from the cooling system. If any of them is d3. Check and cleaning of rear view mirrors
abnormal, carry out a repair. Check and repair any abnormalities and breakage
a5. Check for leakage from fuel line of the rear view mirrors.
Check any fuel leaks and damaged hoses and Clean the mirror surfaces and adjust their angles so
tubes. If any of them is abnormal, carry out a repair. that the operator can see the area behind machine
a6. Check of radiator and dirt removal at the operator's seat.
Check and remove any accumulated dirt and e1. Check of gauges and monitors for
combustibles (dead leaves, twigs, etc.) around the abnormalities
radiator. Check the gauges and monitors inside the operator
a14. Check around KDPF and dirt removal cab. If any of them is abnormal, replace it.
Check and remove any accumulated dirt and Clean up the surfaces.
combustibles (dead leaves, twigs, etc.) around e2. Check of seat belt and mounting hardware
KDPF. Check the hooks, locks and hook fittings for
a15. Check around KDPF for gas leakage damage. If any of them has a problem, replace.
Check piping between the turbocharger and KDPF
and joints of KDPF for gas leakage (sticking soot,
etc.) If any abnormality is found, repair.
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage and
hoses for cracks and excessive wear, check that the
clearance between them is within the normal range,
and then repair any abnormalities.
b3. Check of hydraulic equipment, hydraulic
tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check around battery and dirt removal
WA470-7 40-17
40 Troubleshooting
General information on troubleshooting
40-18 WA470-7
40 Troubleshooting
General information on troubleshooting
5. Remove drain hose (4). Reuse the drain hose leads to leakage of fuel. If the filter cartridge is
and clip. too loose, fuel will also leak from the packing.
6. By using the filter wrench, turn filter cartridge (1) Therefore, be sure to observe the fastening
counterclockwise to remove it. The filter angle.
cartridge (1) is one with transparent cup (3). 10.Fasten it by using filter wrench 1/2 to 3/4 turns.
7. Make sure that drain valve (2) which is provided At that time, take care not to damage or deform
in the lower part of transparent cup (3) of the the filter cartridge.
new filter cartridge is firmly tightened. 11.Install drain hose (4).
12.After replacing the filter cartridge, start the
3 Tightening torque of drain valve:
engine and run it at low idle for 10 minutes.
2.5 to 3.4 Nm {0.25 to 0.35 kgm} Check for fuel leakage from the filter seal
surface and transparent cup mounting face. If
there is any leakage of fuel, check the fastening
condition of the filter cartridge.
If the fuel still leaks, follow Step 1 to 6 to remove
the filter cartridge, then check the packing
surface for damage or foreign material. If any
damage or foreign material is found in the
packing, replace the cartridge with a new one,
then repeat Steps 7 to 10.
a10. Check of fuel main filter
k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts
8. Clean the filter holder, fill the new filter cartridge have cooled down before starting the work.
with clean fuel, apply thin film of oil to the
packing surface, then install it to the filter holder. k High pressure is generated inside the engine
fuel piping system when the engine is
k When adding fuel, do not remove cap (A) running. Stop the engine and wait at least 30
at the center. Always fill fuel from dirty seconds until the inner pressure is released
side of eight small holes (B). and then replace the filter .
k After adding fuel, remove cap (A) at the k Never bring flames near fuel.
center and install fuel filter.
k When using fuel feed pump, be sure not to
k Always fill with clean fuel. Be careful not loosen air bleeding plug in fuel circuit. While
to let any dirt or dust get into the fuel. In the fuel feed pump is in operation, pressure
particular, since center portion is the is applied to the fuel circuit. Do not loosen
clean side, do not remove cap (A) when the air bleeding plug at this time, since the
adding fuel. Be careful not to let dirt or fuel may spout out.
dust get into the center clean side.
a A special filter with high-efficiency filtering
properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel filter cartridge is used, foreign
material may enter and it may cause problems in
the injection system. Do no use substitute parts.
a During testing or maintenance of the fuel system,
take extreme care not to allow any foreign
9. When installing, fasten it by finger until the material to enter the fuel system. If any dust or
packing surface contacts the seal surface of the other material sticks to any part, wash the part
filter holder. If the filter cartridge is fastened too thoroughly with clean fuel.
much, the packing will be damaged and this
WA470-7 40-19
40 Troubleshooting
General information on troubleshooting
• Prepare a container to receive drained oil. a Continue the supply of fuel until the fuel
• Prepare a filter wrench. gauge monitor turns to blue.
1. Stop the engine and wait until the temperature of (Check the fuel level with monitor after
each part to drop. turning the starting switch to ON position.)
2. Open the engine side cover on the right side of 8. Open the side cover on the right side of engine.
the machine. 9. Tilt switch (2) for the fuel feed pump in the
3. Place a container to receive drained oil under engine room to ON position.
filter cartridge (1).
a The fuel feed pump operates and lamp (3)
flashes.
6. When installing, fasten it by finger until the 10.After the specified time (approximately 6
packing surface contacts the seal surface of the minutes and 30 seconds), lamp (3) goes out
filter holder. Then fasten filter cartridge 1/2 to 3/4 automatically and the fuel feed pump stops.
turns. If the filter cartridge is fastened too much, a11. Check of engine oil level (in oil pan) and
the packing will be damaged and this leads to type
leakage of fuel. If the filter cartridge is too loose,
fuel will also leak from the packing. Therefore, k Immediately after the engine is stopped, its
be sure to observe the fastening angle. parts and oil are still very hot, and may cause
7. Supply fuel to the fuel tank. burn injury. Accordingly, wait until all parts
have cooled down before starting the work.
40-20 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-21
40 Troubleshooting
General information on troubleshooting
40-22 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-23
40 Troubleshooting
General information on troubleshooting
40-24 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-25
40 Troubleshooting
General information on troubleshooting
40-26 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-27
40 Troubleshooting
General information on troubleshooting
1. Stop the engine and remove plug (1). a Since lubricating oil of a different brand is
used for the axle with ASD (Anti-Slip
a Remove mud and dirt from around plug (1),
Differential), be sure to use the specified
then remove plug.
lubricating oil.
2. Wipe off oil on dipstick (G) attached to plug (1)
5. If the oil level is above the top groove (H), drain
by using a piece of cloth.
the excess oil from drain plug (P), then check
A: Front
the oil level again.
6. If the oil level is appropriate, install plug (1).
3 Tightening torque: 127 to 177 Nm {13
to 18 kgm}
b8. Bleeding air
• For the bleeding air from the fuel system, see
Testing and adjusting, "Bleeding air from fuel
circuit".
• For the bleeding air from the hydraulic system,
see Testing and adjusting, "Bleeding air from
each part".)
c. Electric equipment
c1. Check of battery terminal for looseness and
B: Rear
corrosion
• Check battery terminals for looseness and
corrosion.
• Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the batteries.
c2. Check of alternator terminal for looseness
and corrosion
• Remove the engine undercover.
• Check alternator terminals B, R and E for open
circuit, loosening and corrosion.
c3. Check of starting motor terminal for
looseness and corrosion
3. Set oil level gauge (G) as shown in the figure to
• Check starting motor terminals B, C and R for
the right.
open circuit, loosening and corrosion.
(2): Axle
c4. Check of battery voltage (with engine
(3): Spot-faced surface
stopped)
4. Oil level is appropriate if it is between two
grooves (H) and (L) of oil level gauge. • Check the battery voltage by using the battery
If the oil does not reach the lower groove (L), tester while the engine is stopped.
supply axle oil from oil filler port (F). c5. Check of battery electrolyte level
• Check before operating the machine.
k Do not use the battery if the battery
electrolyte level is below the LOWER LEVEL
line. This will accelerate deterioration of the
inside of the battery and reduce the service
life of the battery. In addition, it may cause an
explosion.
40-28 WA470-7
40 Troubleshooting
General information on troubleshooting
a Do not add the battery fluid above the UPPER • (B) Low: Since the electrolyte level does not
LEVEL line. If done, the fluid may leak and the reach the sleeve bottom, the shape of the
coating surface may be damaged or the parts electrode plates will appear straight.
may be corroded. 3. After adding the refined water, tighten the cap.
a To avoid freezing, add the purified water (such
as a commercial battery fluid) before starting the
work in the next day.
• When checking the electrolyte level through the
side face of the battery
1. Wipe and clean the battery surface, especially
around the battery level lines with a wet cloth,
and check to see that the battery fluid is
between the UPPER LEVEL and LOWER
LEVEL lines.
a Do not clean the battery with a dry cloth
since static electricity may cause an
explosion.
a If the fluid exceeds the UPPER LEVEL,
remove the fluid using a dropping pipette or
others until the fluid drops to the UPPER
LEVEL. When you have removed the fluid
from the battery, neutralize it with the baking
soda (sodium bicarbonate) and wash it away
with a large quantity of water.
c6. Check of wiring harness for discoloration,
burn and cover peeling
• Check the wiring harness and cables for
discoloration and burn.
2. If the battery fluid drops below the center a If discolored or burnt, the circuit may be shorted
position between the UPPER LEVEL and or grounded.
LOWER LEVEL lines, remove the cap and add • Check the wiring harnesses and cables for
the fluid (such as a commercial battery fluid) damage and peeling of the covers.
immediately until the fluid reaches the UPPER • If any abnormality is found, repair or replace the
LEVEL. wiring harness or cables.
a After adding the refined water, tighten the c7. Check for coming off of wiring harness
cap securely. clamp and sagging of wiring harness
a If the fluid exceeds the UPPER LEVEL, • Check wiring harness for sagging and looseness
remove the fluid using a dropping pipette or due to coming off of harness clamp
others until the fluid drops to the UPPER a In particular, carefully check the wiring harness
LEVEL. When you have removed the fluid around the hot and movable parts.
from the battery, neutralize it with the baking • If removed from the clamp, secure it with the
soda (sodium bicarbonate) and wash it away clamp.
with a large quantity of water.
• When electrolyte level cannot be checked
through the side face of the battery
1. Remove the cap from the top of battery.
2. Observe fluid level port (3), and check the fluid
level. If the fluid level is below sleeve (4), always
add the fluid (such as a commercial battery fluid)
until it reaches the bottom of sleeve (4) (the
UPPER LEVEL).
• (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
WA470-7 40-29
40 Troubleshooting
General information on troubleshooting
40-30 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-31
40 Troubleshooting
General information on troubleshooting
c10. Check the connector pins for corrosion, • Wipe and remove any foreign material with a
bending and deformation. cloth or others, and blow the air to clean the
connector.
• Disconnect the connectors, and check their pins
for corrosion, bending, sinking than other pins,
and extension of female pins.
• If pins are defective, repair or replace them.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
disconnect the connectors 10 times)
c11. Check of connector for water and foreign
material insertion.
• Disconnect connectors, and check them for
insertion of water or foreign materials.
c12. Check of wiring harness for open or short
circuit
• Check the connection (crimped part) between
connector pins and wiring harness.
• If the line is open as shown as (A), repair or
replace the wiring harness or cables.
40-32 WA470-7
40 Troubleshooting
General information on troubleshooting
• A fusible link is a large-capacity fuse. 3. Start and warm up the engine and measure the
• If a fuse is corroded and coated with white voltage while running the engine at a medium or
powder, or there is any play between the fuse a higher speed.
and fuse holder, replace the fuse. • If the voltage is abnormal, repair or replace
• Replace each fuse with the one of the same the alternator.
capacity.
Open the engine left side cover and remove cover
(1).
WA470-7 40-33
40 Troubleshooting
General information on troubleshooting
a When carrying out troubleshooting of an electric 5) Disconnect connectors M01B (7), L18A (8),
circuit related to the transmission controller, and L18B (9).
monitor controller, engine controller, work 6) Remove cover (10).
equipment controller , or KOMTRAX
communication MODEM, expose the related
connectors according to the following procedure.
a Disconnect and connect the connectors, which
have a special locking device, according to the
following procedure.
Preparation (WA470-C050-42C-K-00-A)
2. Engine controller
1) Open the right engine side cover.
a The engine controller is mounted on the
engine (front of the machine).
2) Remove cover (1) and fuel feed pump switch
(2).
40-34 WA470-7
40 Troubleshooting
General information on troubleshooting
3) Insert or connect T-adapters for 4) Remove bolts (5) and (6) (2 pieces each).
troubleshooting to connectors J1 (3), J2 (4),
and EC3 (5) of engine controller.
a Since the connectors is secured with
screws, loosen them before
disconnecting the connector.
a When restore them, tighten the screws to
the specified torque.
3 Screw:
3 ± 1 Nm {0.3 ± 0.1 kgm}
3. Transmission controller
1) Fold operator's seat (1) forward.
2) Remove box mounting bolts (2) (4 pieces)
and remove the box.
WA470-7 40-35
40 Troubleshooting
General information on troubleshooting
4. Monitor controller
1) Fold operator's seat (1) forward.
2) Remove box mounting bolts (2) (4 pieces)
and remove the box. 7) Unlock connectors (11) and (12).
a Shift lever (c) inward while pressing tab
(b). (as shown in the right of the following
figure)
40-36 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-37
40 Troubleshooting
General information on troubleshooting
40-38 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-39
40 Troubleshooting
General information on troubleshooting
2. Press the inverted triangle key [▽] twice on the Service Menu screen to select "03 Abnormality Record".
3. Press the Enter key (check mark) to validate it, and go to the "Abnormality Record" screen.
40-40 WA470-7
40 Troubleshooting
General information on troubleshooting
4. Press the Enter key (check mark) on the "Abnormality Record" screen, and go to the "Mechanical
Systems" screen.
5. Press the inverted triangle key [▽] and make sure that the following failure codes are not generated.
Record all failure codes on a paper.
a A failure code of the mechanical system cannot be deleted.
6. Return to the "Abnormality Record" screen by pressing the Return key (explained above).
7. Go to the "Electrical system abnormality record" similarly to steps 2 and 3.
8. Press the inverted triangle key [▽] and make sure that the following failure codes are not generated.
Record all failure codes on a paper.
WA470-7 40-41
40 Troubleshooting
General information on troubleshooting
a If "E" is displayed at the left to the failure code, this code is "active" (that is, this failure still continues or
its recovery is not verified yet). If "E" is not displayed, the failure code is "inactive" and the code will be
cleared in the subsequent clearing step. Be sure to record this failure code on a paper.
9. Hold down the inverted triangle key [▽], and press numeric keys [1], [2] and [3] in this order to go to the
"Clear mode". (Same as 1)
10.Press the Menu switch of the switch panel (as explained above).
11.Press the Enter key (check mark) to clear all failure codes.
12.Return to the "Electrical Systems" screen by pressing the Return key (explained above). Check if a failure
code is still displayed or not, and record it on a paper.
13.Return to the "Abnormality Record" screen by pressing the Return key (explained above).
40-42 WA470-7
40 Troubleshooting
General information on troubleshooting
Troubleshooting
No. Symptom of failure
Index
Action level and failure code
Action level is displayed on machine monitor. Press Enter switch (check
1 mark) to display "Occurred error list". Perform
Failure code is displayed on mechanical system abnormality record. troubleshooting for
2
failure code.
3 Failure code is displayed on electrical system abnormality record.
Symptom related to engine
4 Engine does not start E-1, S-1
5 Engine does not crank when starting switch is turned to "START" position. E-1, S-1
6 Engine cranks but no exhaust smoke comes out. S-2
7 Fuel is being injected but engine does not start. S-3
8 Engine startability is poor. S-4
9 Engine does not pick up smoothly. S-5
10 Engine stops during operation. S-6
11 Engine runs rough or is unstable. S-7
12 Engine lacks power. S-8
13 KDPF gets clogged in a short time S-9
14 Engine oil consumption is excessive. S-10
15 Oil becomes contaminated quickly. S-11
16 Fuel consumption is excessive. S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down). S-13
18 Engine oil pressure drops. S-14
19 Fuel mixes into engine oil. S-15
20 Water mixes into engine oil (milky). S-16
21 Coolant temperature rises too high (overheating). S-17
22 Unusual noise is heard. S-18
23 Vibration is excessive. S-19
24 Air cannot be bled from fuel circuit. S-20
25 Active regeneration of KDPF is performed frequently. S-21
26 Active regeneration takes time. S-22
27 White smoke is exhausted during active regeneration. S-23
28 Manual preheating system does not work. E-2
29 Automatic preheating system does not work. E-3
30 While preheating is working, preheating monitor does not light up. E-4
When operating engine power mode selector switch, engine mode selector
31 function does not operate properly. E-38
32 Fuel feed pump does not operate properly. E-57
Symptom related to travel
33 Machine does not move off. H-1
34 Torque converter lockup clutch is not disengaged (engine stalls). H-2
35 Torque converter lockup clutch is not engaged. H-3
Travel speed is slow, bucket thrust force is weak, gradability is low, or gear
36 speed does not shift. H-4
37 Large shocks are made when machine starts or gear is shifted. H-5
38 Machine starts or gear speed shifts with long time lag. H-6
39 Torque converter oil temperature is high. H-7
Steering component
40 Machine does not turn. H-8
41 Turning response is poor. H-9
42 Steering wheel is heavy to turn. H-10
43 Machine sways or large shocks are made while machine turns. H-11
44 Turning radius differs between right and left turns. H-12
WA470-7 40-43
40 Troubleshooting
General information on troubleshooting
Troubleshooting
No. Symptom of failure
Index
Brake component
45 Wheel brakes do not work or they are weak. H-13
46 Wheel brakes are not released or drag. H-14
47 Parking brake does not work or it is weak. H-15
Parking brake is not released or it drags (including emergency release
48 system) H-16
Symptom related to work equipment
49 Boom does not rise. H-17
50 Boom moves slow or boom lacks lifting force. H-18
51 Rising boom slows down at certain height. H-19
52 Lift cylinders do not serve to hold bucket on ground H-20
53 Hydraulic drift of boom is large. H-21
54 Boom moves up and down during operation. H-22
55 Bucket does not tilt back. H-23
56 Bucket moves slow or bucket lacks tilt back force. H-24
57 Bucket decelerates during tilt-back operation. H-25
58 Bucket cylinder does not hold bucket on ground. H-26
59 Hydraulic drift of bucket is large. H-27
Bucket tilts back and forth during carrying load (work equipment valve in
60 HOLD). H-28
61 Boom and bucket control levers do not move smoothly and heavy to move. H-29
Operating work equipment causes engine speed to lower significantly or
62 engine to stall. H-30
63 Large shocks are made when work equipment starts and stops working. H-31
When single work equipment is relieved hydraulically, other work equipment
64 H-32
moves.
65 E.C.S.S. (travel damper) does not work and machine pitches and bounces. H-33
Bucket does not stop at the position which is set with remote bucket
66 positioner H-34
Symptom related to fan
67 Fan speed is abnormal (too high or low, or fan does not rotate) H-35
68 Unusual noise is heard from around fan. H-36
Symptom related to machine monitor
All of LCD unit, LED unit, and meter unit on machine monitor displays
69 nothing. E-5
70 LCD unit on machine monitor displays nothing. E-6
Backlight of LCD unit on machine monitor is abnormal (backlight goes out or
71 flickers). E-7
72 LCD on machine monitor does not display properly. E-8
73 Meter unit display on machine monitor is abnormal E-9
74 Night lighting lamp of meter unit on machine monitor is abnormal. E-10
75 Caution LED on machine monitor is abnormal E-11
LED of switch panel on machine monitor is abnormal or switches does not
76 operate properly. E-12
77 2 switches operation of switch panel on machine monitor does not function. E-13
78 Switch panel buzzer of machine monitor is abnormal. E-14
79 Rearview monitor does not light up or backlight flickers. E-15
80 Rearview monitor images are not displayed clearly. E-16
81 Rearview monitor brightness cannot be adjusted. E-17
82 Night lighting lamp of rearview monitor is abnormal. E-18
Some items of gauges and caution lamps on machine monitor are not
83 displayed properly. E-19
40-44 WA470-7
40 Troubleshooting
General information on troubleshooting
Troubleshooting
No. Symptom of failure
Index
Parking brake indicator lamp does not light when the parking brake is set to
84 ON (Parking) position (stays in NEUTRAL). E-20
When brake accumulator oil pressure drops, the brake oil pressure caution
85 lamp does not light. E-21
86 Air cleaner clogging indicator lamp does not light. E-22
87 Radiator coolant level caution lamp does not light. E-23
Indication of hydraulic oil temperature gauge does not increase, or hydraulic
88 oil temperature caution lamp does not light. E-24
Indication of torque converter oil temperature gauge does not increase, or
89 torque converter oil temperature caution lamp does not light. E-25
90 Fuel level gauge does not indicate correct level. E-26
91 Seat belt caution lamp indication is abnormal. E-27
92 Alarm buzzer does not sound. E-30
93 When starting switch is in ON position, alarm buzzer does not stop sounding. E-31
"Procedure for testing
Air conditioner does not operate normally (including failure codes related to
94 and troubleshooting" in
air conditioner).
Chapter 80
Others
95 Horn does not sound. E-28
96 Horn does not stop sounding. E-29
97 Kickdown does not work when kickdown switch is turned ON. E-32
98 The hold switch does not work when it is pressed. E-33
Parking brake does not work even if it is applied, or the brake drags when
99 traveling in forward or reverse while parking brake is released. E-34
100 Transmission cut-off mode is not selected or not released. E-35
101 Transmission cut-off position cannot be released. E-36
102 Direction selector (FNR) switch mode is not selected or not released. E-37
103 Flow of loader pump does not increase from the minimum rate. E-39
104 ECSS function cannot be selected or cannot be released. E-40
105 None of headlamp, clearance lamp, and tail lamp lights. E-41
106 Clearance lamp and tail lamp does not light up. E-42
107 Both "High and Low beams" of headlamp do not light up or go out. E-43
108 The headlamp "Low beam" does not light up or go out. E-44
109 The headlamp "High beam" does not light up or go out. E-45
110 Front working lamp does not light up or go out. E-46
111 Rear working lamp does not light up or go out. E-47
112 All of turn signal lamps and hazard lamps do not light up or go out. E-48
113 Turn signal lamps do not light up or go out. E-49
114 Hazard lamp does not light up or go out. E-50
115 Brake lamp does not light up or stays lighted. E-51
116 Backup lamp does not light or continues to light. E-52
117 Backup buzzer does not sound or continues to sound. E-53
118 Front wiper does not operate. E-54
119 Rear wiper does not operate. E-55
120 Window washer does not operate. E-56
121 KOMTRAX system does not operate normally. E-58
WA470-7 40-45
40 Troubleshooting
General information on troubleshooting
(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen
Display on Failure
machine of the machine monitor
machine monitor
monitor
Detail of Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by
controller the machine monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is
machine performed by the machine monitor or controller.
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective — <Contents of description>
Open or short circuit in wiring • Procedure
2
harness • Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective and resistance between A and B.
contact of connector)
Ground fault in wiring harness a "Between A and ground" means the measurement of voltage,
4 resistance or others between terminal A and the place which has
(contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal
5 Hot short circuit head bolt or bolt hole which has no rust, etc.
• Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness
6 • Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power circuit comes into
contact with the power circuit accidentally.
• Short circuit
An independent wire in the harness erroneously comes into contact
with another independent wire.
(poor insulation at connector and others)
40-46 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-47
40 Troubleshooting
General information on troubleshooting
Number
Connector No. Connector type of pins
Equipment name Address
1.PS DT 2 1st solenoid AE-9
1.SW DT 2 1st fill switch AE-8
2.PS DT 2 2nd solenoid AJ-4
2.SW DT 2 2nd fill switch AJ-4
3.PS DT 2 3rd solenoid AJ-4
3.SW DT 2 3rd fill switch AJ-3
4.PS DT 2 4th solenoid AE-8
4.SW DT 2 4th fill switch AE-8
AL1 DT 8 Air conditioner unit O-3
AR1 DT 6 Intermediate connector H-2
BREAKOUT
(E24) FRAMATOME 24 Intermediate connector AO-6
B-RES DT 3 Terminating resistor (120 z) AL-3
C01 PA 9 Radio Z-9
C02 M 2 Speaker (R.H.) AC-9
C03 M 2 Speaker (L.H.) AD-8
C04 DT 2 Front working lamp (R.H.) Y-8
C05 DT 2 Front working lamp (L.H.) AD-5
C07 KES 1 2 Room lamp AD-7
C08 M 1 Door switch (R.H.) Y-8
C09 M 1 Door switch (L.H.) AD-6
C10 2 Cigarette lighter O-2
C12 M 6 Front wiper motor M-3
C15 M 4 Rear wiper motor AD-5
C18 DT 2 Warning lamp AA-9
C18A M 1 Revolving warning lamp AB-9
C22 DT 3 Revolving warning lamp AA-9
C25 DT 4 Intermediate connector Y-8
C29 M 1 Rear glass heater Y-6
C33 1 Rear glass heater AD-7
C35 1 Rear glass heater AB-9
C39 Terminal 1 Ground (radio body) Z-8
C40 Terminal 1 Ground AC-8
C91 M 1 Intermediate connector (warning lamp) Y-6
C140 DT 4 Intermediate connector W-9
C141 DT 6 Intermediate connector W-9
CL1 SWP 8 Intermediate connector Y-4
CL2 SWP 12 Intermediate connector Y-5
CL21 SWP 6 Intermediate connector V-9
CL24 X 2 Intermediate connector Q-7
CL27 SWP 6 Side wiper Y-4
CN1 DT 2 Injector #1 AK-8
CN2 DT 2 Injector #2 AK-8
CN3 DT 2 Injector #3 AK-9
CN4 DT 2 Injector #4 AL-9
CN5 DT 2 Injector #5 AM-9
CN6 DT 2 Injector #6 AN-9
COMBI DT 3 Front right combination lamp C-6
COMBI DT 3 Front left combination lamp F-1
D04 YAZAKI 2 Diode X-4
40-48 WA470-7
40 Troubleshooting
General information on troubleshooting
Number
Connector No. Connector type of pins
Equipment name Address
D05 YAZAKI 2 Diode W-4
D06 YAZAKI 2 Diode W-6
D07 YAZAKI 2 Diode W-4
D08 YAZAKI 2 Diode W-4
D09 YAZAKI 2 Diode W-4
D11 YAZAKI 2 Diode W-6
D12 YAZAKI 2 Diode W-6
DIODE DT 2 Diode AH-1
DOSER FRAMATOME 2 HC dosing solenoid AM-4
E01 DT 2 Intermediate connector I-2
E02 Terminal 1 Alternator terminal E L-6
E04 Terminal 1 Alternator terminal R L-5
E05 Terminal 1 Heater relay K-1
E06 Terminal 1 Heater relay L-3
E06A DT 2 Diode K-4
E07A Terminal 1 Heater relay L-2
E07B Terminal 1 Electrical intake air heater (ribbon heater) I-9
E10 DT 2 Freon compressor magnet clutch I-9
E14A Terminal 1 Ground AL-1
E14B Terminal 1 Ground AL-2
E14C Terminal 1 Ground AN-6
E15 Terminal 1 Ground J-3
E25 FRAMATOME 4 KDPF pressure sensor AO-6
E26 DT 4 KDPF temperature sensor AN-6
E27 DT 2 Engine oil level sensor L-3
E28 DT 12 Pump timer switch AO-6
E29 DT 2 Fuel feed pump AM-1
E33 DT 6 Intermediate connector I-1
E45 DT 2 Dust indicator H-9
EC3 DRC 60 Engine controller AN-6
EGR-SOL DT 2 EGR valve solenoid AL-5
ER1 DT 12 Intermediate connector I-3
ER2 DT 12 Intermediate connector I-3
ER3 DT 2 Intermediate connector I-2
ER4 DT 6 Intermediate connector L-2
F.PS DT 2 F solenoid AE-9
F.SW DT 2 F fill switch AE-9
F01 DT 6 Intermediate connector C-7
F02 DT 6 Intermediate connector E-8
F03 2 Horn A-2
F04 2 Horn B-4
F10 DT 3 Ladder pump pressure sensor C-1
F11 DT 3 Boom potentiometer sensor C-7
F12 DT 3 Boom bottom pressure sensor D-1
F13 DT 3 Boom head pressure sensor E-1
F20 DT 2 E.C.S.S. solenoid A-3
F21 DT 2 Bucket TILT EPC A-3
F22 DT 2 Bucket DUMP EPC A-1
F23 DT 2 Boom RAISE EPC A-3
F24 DT 2 Boom LOWER EPC A-1
F25 DT 2 3rd ATT EXT EPC A-2
F26 DT 2 3rd ATT RET EPC B-4
WA470-7 40-49
40 Troubleshooting
General information on troubleshooting
Number
Connector No. Connector type of pins
Equipment name Address
F29 DT 2 Diode A-4
F30 DT 3 Intermediate connector D-8
F31 DT 2 Boom EPC cut-off solenoid A-4
F32 DT 3 Bucket angle signal B-1
F40 Terminal 1 Ground (front frame) F-1
FR1 DT 12 Intermediate connector E-1
FR2 DT 8 Intermediate connector E-1
FR3 DT 12 Intermediate connector E-1
FR4 DT 6 Intermediate connector F-1
FS6 X 1 Intermediate connector W-2
FS7 X 1 Intermediate connector W-2
FS8 Terminal 15 Fuse box X-7
FS9 Terminal 15 Fuse box X-8
G SUMITOMO 3 G sensor AM-5
G04 DT 2 Rear working lamp (L.H.) L-7
G05 DT 2 Rear working lamp (R.H.) J-9
G06 DT 4 Rearview camera K-9
GR1 DT 12 Intermediate connector L-6
G-RES DT 2 Fuel supply pump pull-up resistor AL-2
HEAD DT 3 Right headlamp C-5
HEAD DT 3 Left headlamp F-1
INJ DTA 12 Intermediate connector AN-9
J01 20 Junction connector X-2
J02 20 Junction connector T-2
J03 20 Junction connector X-2
J04 20 Junction connector X-2
J05 20 Junction connector X-2
J06 20 Junction connector T-2
J07 20 Junction connector T-2
J08 20 Junction connector T-2
J09 20 Junction connector V-5
J1(EC1) DRC 60 Engine controller AO-6
J1939 3 CAN_C AN-9
J10 20 Junction connector X-2
J11 20 Junction connector X-2
J12 20 Junction connector T-2
J13 20 Junction connector T-2
J14 20 Junction connector T-2
J15 20 Junction connector T-2
J16 20 Junction connector O-4
J17 20 Junction connector O-4
J18 20 Junction connector R-2
J19 20 Junction connector O-4
J2(EC2) DRC 60 Engine controller AN-6
J20 20 Junction connector X-2
J21 20 Junction connector X-2
J22 20 Junction connector V-5
J41 20 Junction connector V-4
J42 20 Junction connector V-4
J43 20 Junction connector V-4
J44 20 Junction connector V-4
JC01 8 Junction connector AO-7
40-50 WA470-7
40 Troubleshooting
General information on troubleshooting
Number
Connector No. Connector type of pins
Equipment name Address
JC02 8 Junction connector AO-7
JL1 DT 8 Intermediate connector U-8
JL2 12 Joystick lever switch U-8
JL3 Relay 6 Joystick safety relay V-7
JT1 DT 8 Junction connector AG-1
JT2 DT 6 Junction connector AI-2
L02 DT 12 Gear speed switch O-2
L04 SWP 12 Lighting switch O-1
L05 DT 2 Horn switch N-1
L09 DT 2 Brake lamp switch T-2
L11 2 Air suspension seat S-2
L14 DT 4 Boom lever M-8
L15 DT 4 Bucket lever M-8
L17 DT 6 DC/DC converter U-8
L18A YAZAKI 2 12 V socket R-8
L18B YAZAKI 2 12 V socket Q-8
L19 M 4 Flasher unit U-2
L20 M 2 Alarm buzzer X-8
L21 S 10 Wiper switch O-1
L23 DT 4 4th EPC lever O-7
L28A DT 4 Boom EPC lever N-6
L28B 2 Boom EPC lever M-8
L29A DT 4 Bucket EPC lever O-7
L29B 2 Bucket EPC lever M-8
L30 DT 4 3rd EPC lever O-7
L31 KES 1 6 Wiper timer V-4
L32 DT 12 Intermediate connector P-8
L33 DT 12 Intermediate connector O-7
L34 DT 12 Intermediate connector P-7
L35 DT 12 Intermediate connector P-7
L36A DT 4 Intermediate connector V-2
L40 DT 3 Intermediate connector M-1
L41 VCH 10 Multi-coupler switch M-1
Intermediate connector (load meter printer wiring
L44 M 6 harness) R-8
L50 Terminal 1 Ground O-5
L51 Terminal 1 Ground O-6
L52 Terminal 1 Ground V-3
L61 DRC 24 Transmission and fan pump controller S-9
L62 DRC 40 Transmission and fan pump controller S-9
L63 DRC 40 Transmission and fan pump controller S-9
L71 DRC 24 Work equipment controller S-9
L72 DRC 40 Work equipment controller T-9
L73 DRC 40 Work equipment controller T-9
L80A 070 18 KOMTRAX terminal V-6
L80B 070 12 KOMTRAX terminal V-5
L100 Terminal 1 Ground (floor) V-3
L111 Relay 5 Relay No. 13 (turn signal lamp and hazard lamp 1) X-8
L112 Relay 5 Relay No. 12 (fan pump) V-6
L113 Relay 5 Relay No. 11 (personal lock) V-7
L114 Relay 5 Relay No. 5 (beacon lamp) X-7
L115 Relay 5 Relay No. 5 (yellow working lamp) V-7
WA470-7 40-51
40 Troubleshooting
General information on troubleshooting
Number
Connector No. Connector type of pins
Equipment name Address
L116 Relay 5 Relay No. 21 (neutral safety) X-9
L117 Relay 5 Relay No. 20 (backup lamp) W-9
L118 Relay 5 Relay No. 19 (stop lamp) W-9
L119 Relay 5 Relay No. 18 (horn) W-9
L120 Relay 5 Relay No. 17 (parking brake) V-9
L121 Relay 5 Relay No. 14 (neutral hold) V-8
L122 Relay 6 Relay No. 3 (turn signal lamp and hazard lamp 2) V-7
L125 Relay 5 Relay No. 6 (preheat) V-8
L126 Relay 5 Relay No. 6 (emergency steering) V-9
L127 Relay 5 Relay No. 15 (front working lamp) V-9
L128 Relay 5 Relay No. 9 (rear working lamp) V-8
L129 Relay 5 Relay No. 4 (rear heated wire glass) X-6
L131 Relay 5 Relay No. 7 (headlamp) V-8
L132 DT 6 Intermediate connector U-2
L133 Relay 5 Relay No. 8 (automatic idle stop parking brake) V-8
L180 DT 2 Intermediate connector S-2
L/C.PS DT 2 Torque converter lockup solenoid AE-9
LDR_L DT 3 Left LED tail and step lamp L-7
LDR_R DT 3 Right LED tail and step lamp K-9
LDW_L DT 2 Left LED backup lamp L-6
LDW_R DT 2 Right LED backup lamp K-9
LDY_L DT 2 Left turn signal lamp L-6
LDY_R DT 2 Right turn signal lamp K-9
LR1 DRC 70 Intermediate connector C-9
LR2 DT 12 Intermediate connector A-8
LR3 DT 12 Intermediate connector C-9
LR4 DT 12 Intermediate connector C-9
LR5 X 1 Intermediate connector U-2
LR6 #8 1 Intermediate connector A-8
LR7 #8 1 Intermediate connector B-9
LR8 #8 1 Intermediate connector B-9
LR9 #8 1 Intermediate connector B-9
LR11 DT-P 2 Intermediate connector C-8
LR12 #8 1 Intermediate connector A-8
LT1 24-31 31 Intermediate connector U-2
M01A M 3 AUX jack Z-9
M01B M 3 AUX jack Y-5
MCM1_A AMP 80 Monitor controller Q-8
MCM1_B AMP 40 Monitor controller Q-8
MCM2 8 Monitor controller R-8
MDM1 8 Machine monitor N-3
MDM2 AMP 6 Machine monitor N-3
MDM3 AMP 8 Machine monitor N-3
MOM1 AMP 6 Switch panel O-2
NE FRAMATOME 3 Ne speed sensor AM-1
PAMB FRAMATOME 3 Ambient pressure sensor AM-5
PB.PS DT 2 Parking brake solenoid AJ-2
PB.SW DT 2 Parking brake indicator switch AH-1
PCCV FRAMATOME 3 Crankcase pressure sensor AK-9
PCV1 SUMITOMO 2 Supply pump PCV1 AM-5
PCV2 SUMITOMO 2 Supply pump PCV2 AN-5
PD DT 6 Accelerator pedal O-2
40-52 WA470-7
40 Troubleshooting
General information on troubleshooting
Number
Connector No. Connector type of pins
Equipment name Address
PDOSER FRAMATOME 3 Shut off valve pressure sensor AP-5
PDV DT 2 Accelerator pedal O-3
PFUEL AMP 3 Common rail pressure sensor AO-7
PIM FRAMATOME 3 Boost pressure sensor AO-9
POIL FRAMATOME 3 Engine oil pressure sensor AL-5
R.PS DT 2 R clutch solenoid AJ-5
R.SW DT 2 R clutch fill switch AJ-5
R01 Terminal 1 Battery relay L-2
R02 Terminal 1 Slow blow fuse K-3
R03 Terminal 1 Slow blow fuse L-3
R04 Terminal 1 Slow blow fuse K-1
R05 Terminal 1 Slow blow fuse J-3
R06A Terminal 1 Slow blow fuse J-3
R06B Terminal 1 Slow blow fuse K-3
R07 Terminal 1 Battery relay I-2
R08 Terminal 1 Emergency steering relay I-2
R10 Terminal 1 Slow blow fuse K-3
R11 Terminal 1 Slow blow fuse J-3
R13 Terminal 1 Emergency steering relay I-1
R14 Terminal 1 Emergency steering relay J-1
R15 Terminal 1 Battery relay K-1
R16 Terminal 1 Battery relay K-1
R20 DT 6 Intermediate connector K-4
R21 DT 6 Intermediate connector B-5
R22 Terminal 1 Ground A-5
R29 DT 2 Fan pump EPC G-9
R32 DT2 2 Coolant level sensor F-9
R33 DT 2 Fuel level sensor L-1
R37 DT 2 Emergency steering pressure sensor G-1
R43 KES_1 2 Front windshield washer H-2
R45 KES_1 2 Rear windshield washer H-2
R47 DT 2 Hydraulic oil temperature sensor E-9
R50 Terminal 1 Ground (rear frame) K-4
R52 DT 2 Front brake pressure switch D-8
R54 DT 2 Rear brake pressure switch E-8
R58 DT 2 Backup alarm buzzer J-9
R59 DT 2 Fan solenoid L-8
R60 DT 2 Brake oil temperature sensor H-2
R61 DT 2 Operating lamp B-7
R71 DT 2 Loader pump EPC G-9
R73 DT 3 Brake oil temperature sensor G-1
R86 3 Steering pump pressure sensor F-9
R87 DT 2 Service connector C-8
R89 DT 2 Fan speed sensor L-8
R90 DT 2 Steering pump EPC H-2
R91 DT 3 Torque converter outlet pressure sensor G-1
R93 FRAMATOME 4 Mass air flow sensor I-9
R96 Terminal 1 Heater relay L-1
R100A DT 8 Intermediate connector F-1
REV IN DT 2 Transmission input shaft speed sensor AI-8
REV OUT DT 2 Transmission output shaft speed sensor AE-6
RVC_1 DT 4 Intermediate connector A-9
WA470-7 40-53
40 Troubleshooting
General information on troubleshooting
Number
Connector No. Connector type of pins
Equipment name Address
RVM1 AMP 12 Rearview monitor O-5
RVM2 AMP 8 Rearview monitor O-6
S_F1 SWP 6 Front working lamp switch M-1
S_F2 SWP 6 Rear working lamp switch M-2
S_F3 SWP 6 Beacon lamp switch M-2
S_F3A SWP 6 Revolving warning lamp switch Q-2
S_F4 SWP 6 ECCS on-off switch M-1
S_F6 SWP 6 Auto greasing switch M-1
S_F7 SWP 6 Daytime light switch N-1
S_FA SWP 6 Parking brake switch N-3
S_FB SWP 6 Hazard lamp M-2
S_FS SWP 6 Engine shutdown secondary switch M-2
S_OH1 SWP 6 Yellow working lamp AA-9
S_OH2A DT 3 Intermediate connector (for Japan) AB-9
S_OHA SWP 6 Rear window glass Z-9
S_RH1 SWP 6 Transmission cut-off/cut-off set switch M-9
S_RH2 SWP 6 Power mode selector switch N-9
S_RH3 SWP 6 Transmission shift mode selector switch N-9
S_RH4 SWP 6 Torque converter lockup switch N-9
S_RH5 SWP 6 Directional selector switch actuation switch N-9
S_RH6 SWP 6 Remote positioner switch O-9
S_RH7 SWP 6 2-stage low idle switch O-9
S_RH8 SWP 6 Emergency steering operation check O-9
S_RHA DT 2 Horn N-6
S_RHB DT 4 Right FNR switch N-6
S_RHC SWP 6 Boom lock switch M-8
S_RV SWP 6 Camera brightness adjustment switch O-5
S40 DT 6 Starting switch N-3
SBS DT2 2 Seat belt switch T-2
SEGR DT 4 EGR valve position sensor AK-5
SI_CH DT 2 SI unit selection switch S-2
SOV1 FRAMATOME 2 Shut off valve solenoid #1 AO-6
SOV2 FRAMATOME 2 Shut off valve solenoid #2 AM-5
SV DT 12 KOMNET SV connector X-8
SVGT DT 3 VGT valve position sensor AM-5
TC.T DT 2 Torque converter outlet oil temperature sensor G-9
TCIN.P DT2 3 Torque converter inlet pressure sensor AI-8
TEL DT 12 Intermediate connector S-2
TGN Terminal 1 Ground (transmission) AJ-2
TIM PKD 2 Boost temperature sensor AO-8
TM.T DT 2 Transmission lubricating oil sensor AG-8
TWTR PKD 2 Coolant temperature sensor AN-1
VGT-REV DT 2 KVGT speed sensor AP-5
VGT-SOL DT 2 KVGT solenoid AK-6
40-54 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-55
40 Troubleshooting
General information on troubleshooting
40-56 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-57
40 Troubleshooting
General information on troubleshooting
40-58 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-59
40 Troubleshooting
General information on troubleshooting
40-60 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-61
40 Troubleshooting
General information on troubleshooting
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-62 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-63
40 Troubleshooting
General information on troubleshooting
40-64 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-65
40 Troubleshooting
General information on troubleshooting
40-66 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-67
40 Troubleshooting
General information on troubleshooting
40-68 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-69
40 Troubleshooting
General information on troubleshooting
40-70 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-71
40 Troubleshooting
General information on troubleshooting
40-72 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-73
40 Troubleshooting
General information on troubleshooting
40-74 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-75
40 Troubleshooting
General information on troubleshooting
40-76 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-77
40 Troubleshooting
General information on troubleshooting
40-78 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-79
40 Troubleshooting
General information on troubleshooting
40-80 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-81
40 Troubleshooting
General information on troubleshooting
40-82 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-83
40 Troubleshooting
General information on troubleshooting
40-84 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-85
40 Troubleshooting
General information on troubleshooting
40-86 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-87
40 Troubleshooting
General information on troubleshooting
40-88 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-89
40 Troubleshooting
General information on troubleshooting
40-90 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-91
40 Troubleshooting
General information on troubleshooting
40-92 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-93
40 Troubleshooting
General information on troubleshooting
40-94 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-95
40 Troubleshooting
General information on troubleshooting
40-96 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-97
40 Troubleshooting
General information on troubleshooting
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
40-98 WA470-7
40 Troubleshooting
General information on troubleshooting
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
WA470-7 40-99
40 Troubleshooting
General information on troubleshooting
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
40-100 WA470-7
40 Troubleshooting
General information on troubleshooting
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
799-601- q
Adapter for DT (green) 8 DT8G q
9080
799-601- q
Adapter for DT (Brown) 8 DT8BR q
9090
799-601- DT12G- q
Adapter for DT (gray) 12 q
9110 R
799-601- q
Adapter for DT (black) 12 DT12B q
9120
799-601- q
Adapter for DT (green) 12 DT12G q
9130
799-601- q
Adapter for DT (Brown) 12 DT12BR q
9140
799-601- Adapter for HD30-18 8 D18-8 q q
9210
799-601- Adapter for HD30-18 14 D18-14 q q
9220
799-601- Adapter for HD30-18 20 D18-20 q q
9230
799-601- Adapter for HD30-18 21 D18-21 q q
9240
799-601- Adapter for HD30-24 9 D24-9 q q
9250
799-601- Adapter for HD30-24 16 D24-16 q q
9260
799-601- Adapter for HD30-24 21 D24-21 q q
9270
799-601- Adapter for HD30-24 23 D24-23 q q
9280
799-601- Adapter for HD30-24 31 D24-31 q q
9290
799-601- q
Plate for HD30 (24-pin) q q
9310
799-601- q
T-box (for ECONO) 24 q q
9320
799-601-
Case q
9330
799-601-
Case q
9340
799-601- q
Adapter for DRC 40 DRC-40
9350
799-601- q
Adapter for DRC 24 DRC-24
9360
799-601- Socket for engine (CRI-T2) 2 G q
9410*
Adapter for engine (CRI-T2) q q
799-601- Adapter for engine (CRI-T3)
PFUEL 3 A3
9420
Oil pressure sensor
799-601- Socket for engine (CRI-T2) q q
2 P
9430* Socket for engine(CRI-T3) PCV
799-601- Socket for engine (CRI-T2) 1, 2, 3
3 q
9440*
WA470-7 40-101
40 Troubleshooting
General information on troubleshooting
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
40-102 WA470-7
40 Troubleshooting
General information on troubleshooting
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
WA470-7 40-103
40 Troubleshooting
General information on troubleshooting
40-104 WA470-7
40 Troubleshooting
General information on troubleshooting
Slow-blow fuse
Type of power Fuse
Fuse No. Destination of power
supply capacity
Spare 1, engine controller circuit, transmission controller
Continuous power circuit, work equipment controller circuit, room lamp circuit,
supply 2 50 A machine monitor circuit, KOMTRAX circuit, hazard lamp
circuit, starting switch B-terminal circuit
Main lamp circuit, machine monitor circuit, air conditioner
circuit, wiper and washer circuit, backup lamp and brake
lamp circuit, work equipment positioner circuit, work
3 50 A
equipment controller circuit, emergency steering circuit,
parking brake circuit, transmission controller circuit, horn
Switched power circuit
supply Rear heated wire glass circuit, air suspension seat and
yellow revolving warning lamp circuit, turn signal lamp
4 50 A circuit, radio circuit, 12V converter circuit, rear working
lamp circuit, front working lamp circuit
5 120 A Heater relay circuit
• Fuse box position and No.
a The fuse box is located at the rear of operator's seat.
WA470-7 40-105
40 Troubleshooting
General information on troubleshooting
a Open the left engine hood, remove cover (1), and then you'll see 50 A slow-blow fuses (2) to (4), and 120
A fuse (5).
40-106 WA470-7
40 Troubleshooting
General information on troubleshooting
WA470-7 40-107
40 Troubleshooting
General information on troubleshooting
1] Stop the engine and wait until the Case 1-4] From the KDPF reset screen, perform
temperature of piping around the engine resetting after KDPF change.
cools down. Remove the KDPF, and then Case 1-5] Start the engine and run at low idle to
remove the KCSF. warm up.
2] Install the replacement KCSF (new or Case 1-6] Perform Regeneration for Service.
reused) to the machine. (In this case, Regeneration for Service may
3] Turn the starting switch to the ON continue for about 2 hours, since it is set to
position. From the KDPF reset screen, terminate when the soot accumulation drops to 2
perform resetting after KDPF cleaning. g/l.)
4] From the KDPF reset screen, perform Case 1-7] When Regeneration for Service is
resetting after KDPF change. completed, check that failure codes (CA1922,
5] Start the engine and run at low idle to CA1921, and CA2639) are not displayed.
warm up. <Case 2> When Regeneration for Service is
6] Perform regeneration for service. performed (KDPF removal unnecessary)
3) If Soot Level High Error 2 (CA1922) is
a If the following conditions are met, the total
displayed
soot sediment is not beyond the limit (9 g/l),
1] Stop the machine and check that failure but the differential pressure has increased
code (CA1922) is displayed on the due to clogging caused by uneven
machine monitor. accumulation of soot. In this case, actual
2] Check the abnormality record for failure regeneration will not result in abnormal
codes "CA2639: Manual Stationary burning. Regeneration for Service can be
Regeneration Request", "CA1921: KDPF performed safely without replacing the KCSF,
Soot Level High Error 1", and "CA1922: and the KCSF can be continuously used
KDPF Soot Level High Error 2"on the after the regeneration.
machine monitor.
• After checking that no sensor related failures
<Case 1> When KDPF is removed and KCSF is
are present, perform this work if any of the
replaced
following is met.
a If the following conditions are met, soot • Time between activation of "CA2639: Manual
accumulation is beyond the limit to burn Stationary Regeneration Request (L01)" and
away by regeneration. The KDPF must be "CA1921: KDPF Soot Level High Error 1
removed to change the KCSF. (L03)" < 360 sec. (KOMTRAX history) or <
• Time between activation of "CA2639: Manual 0.1 h (Abnormality record screen on monitor)
Stationary Regeneration Request (L01)" and • "Time between activation of "CA1921: KDPF
"CA1921: KDPF Soot Level High Error 1 Soot Level High Error 1 (L03)" and "CA1922:
(L03)" X 360 sec. (KOMTRAX history) or X KDPF Soot Level High Error 2 (L04)" <
0.1 h (Abnormality record screen on monitor) 360sec. (KOMTRAX history) or < 0.1 h
and (Abnormality record screen on monitor)
• Time between activation of "CA1921: KDPF [Contents of work]
Soot Level High Error 1 (L03)" and "CA1922: Case 2-1] Start the engine and run at low idle to
KDPF Soot Level High Error 2 (L04)" X360 warm up. From the KDPF reset screen, perform
sec. (KOMTRAX history) or X 0.1 h resetting after KDPF cleaning.
(Abnormality record screen on monitor) Case 2-2] Perform Regeneration for Service.
[Contents of work] (In this case, Regeneration for Service may
Case 1-1] Stop the engine and wait until the continue for about 2 hours, since it is set to
temperature of piping around the engine cools terminate when the soot accumulation drops to 2
down, then remove KCSF. g/l.)
Case 1-2] Install the replacement KCSF (new or Case 2-3] When Regeneration for Service is
reused). completed, check that failure codes (CA1922,
Case 1-3] Turn the starting switch to the ON CA1921, and CA2639) are not displayed.
position. From the KDPF reset screen, perform 3. When cleaning and replacing KDOC
resetting after KDPF cleaning. 1) If cracks or damages are found during
inspection
a When resetting after KDPF cleaning is
performed, changes in ( ) are reflected. 1] If cracks or damages are found in the
(Soot accumulation amount: 9 g/lo8.1 g/l; KDOC, replace it with a new one.
Action level: L04oL03; Failure code: 2] From the KDPF reset screen, perform
CA1922oCA1921) resetting after KDOC change.
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WA470-7 40-109
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General information on troubleshooting
• The machine monitor consists of various independent units that send and receive data to/from the monitor
controller through LIN communication (see the next page).
• As the result, troubleshooting of the machine monitor and related units involves complicated procedures
(see E-5 to E-20 of E-mode troubleshooting).
• Each unit related to the machine monitor has many new type of connectors (see Table 1).
• When performing the troubleshooting of the machine monitor LCD unit (see E-6 to E-8 of E-mode
troubleshooting), refer to "Processing procedure of harness checker for troubleshooting of machine
monitor LCD unit".
Table 1. Detail of connectors related to machine monitor
Con- Num- Manu- Connector
Name of unit nector ber of Type code factur- type, etc. Tool New Remarks
name pins er
MX40008U- –
LCD unit MDM1 8 JAE q
Ma- Q1
chine 070 T-
LED unit MDM2 6 175954-1 AMP q
moni- connector adapter
tor 070 T-
Meter unit MDM3 8 175955-1 AMP q
connector adapter
– MCM1 Measuring
81 Same as
A tool is not a T-
those used
adapter, so
TYCO- in pump Box-type
AMP operating
– MCM 1241434 controller of socket
40 voltage
B hydraulic
cannot be
excavators
measured.
See
Monitor controller "Processing
procedure of
harness
– MX40008N- Harness checker for
MCM2 8 JAE q
Q1 checker troubleshoot-
ing of
machine
monitor LCD
unit".
070 T-
– Switch panel MOM1 6 175954-1 AMP q
connector adapter
070 T-
– RVM1 12 175957-1 AMP
connector adapter
Rear view monitor
070 T-
– RVM2 8 175955-1 AMP q
connector adapter
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WA470-7 40-111
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2. Outline
Mass-produced harness between machine monitor LCD unit and monitor controller: 7831-47-8710
Before being modified
O
After being modified
• Part to be modified is portion P.
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• Cut off the wiring harness at the connector (having no crimped portion), install a heat shrink tube to
each cable to prevent short circuit, and then install a check pin to each cable.
Finished harness checker
Fig. 1 Mass-produced harness between machine monitor LCD unit and monitor controller: 7831-47-8710
a Determine the pin number of each check pin by checking the cable color indicated at portion Q in the
figure or by checking the number of pin on the opposite side to which the cable is connected.
WA470-7 40-113
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3. Preparation
• Materials to be prepared
No. Part name Type Manufacturer Quantity
Japan Aviation
1 Wiring harness 7831-47-8710 1
Electronics Industry
2 Check pin TJ-1-W *1 SATO PARTS 8
Heat shrink tube f5 (Min. 35 mm in Sumitomo Electric
3 SUMI-F2Z-5x0.25 *1 1
length) Industries
Heat shrink tube f5 (Min. 140 mm in Sumitomo Electric
4 SUMI-F2Z-3.5x0.25 *1 1
length) Industries
Labels (with numbers <1> to <8> 1 label each (8
5 printed on them) *2 – –
labels in total)
6 Vinyl tape – – 1
7 Nipper – – 1
8 Wire stripper (for AWG 20-34) – – 1
9 Cutter – – 1
10 Soldering iron – – 1
11 Solder – – 1
12 Dryer *3 – – 1
*1 Can be substituted with an equivalent
*2 They are attached for easy understanding of harness pin number. You may mark numbers on labels.
*3 Can be substituted with a heat gun.
4. Work procedure
• Modification of cables with pin Nos. 3 to 8
1) Use a nipper to cut off the wiring harness at the root of the connector that does not have crimped
portion ((07) in the Fig. 1).
2) Use a wire stripper to remove covers of cables with pin Nos. 3 to 8, 5 mm from the cut end.
a take care not to cut the wire inside the cover.
3) Make six 15-mm heat shrink tubes f3.5 (A).
4) Pass a heat shrink tube (A) over any one of the cut cables, and solder a check pin to the cable.
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5) Slide heat shrink tube (A) of the cable to which the check pin is soldered in step 4) to a position where
the check pin conductor is covered, and use a dryer to contract heat shrink tube (A).
6) Attach the label so that the pin number of the cable is easily read.
a Determine the pin number of each check pin by checking the cable color indicated at portion Q of
Fig. 1 or by checking the number of pin on the opposite side to which the pin is connected.
4. Strip the covers of cables with pin Nos. 1 and 2, 5 mm in length by using a wire stripper.
5. Make one 35-mm heat shrink tube f5 (E).
6. Pass the cut heat shrink tube (E) over the cables with pin Nos. 1 and 2.
WA470-7 40-115
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12.Slide heat shrink tube f5 (E) to a position where it overlaps heat shrink tube f3.5 (F) for cables with pin
Nos. 1 and 2, and then use a dryer to contract heat shrink tube (E).
13.Cut off tape (B) that was stripped from the conduit at an appropriate position, From that position, Wrap
vinyl tape around the cables with pin Nos. 3 to 8 to bind them. This completes the work.
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WA470-7 40-117
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General information on troubleshooting
a KDPF differential pressure sensor is the same as KDPF outlet pressure sensor.
• CA1883 Short-circuit connector for KDPF delta pressure sensor
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WA470-7 40-119
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WA470-7 40-121
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WA470-7 40-123
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General information on troubleshooting
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WA470-7 40-125
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WA470-7 40-127
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WA470-7 40-129
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WA470-7 40-131
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General information on troubleshooting
a In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PT: power train controller
WE: Work equipment controller
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action level columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system or mechanical system) of the service menu.
a The history classification column shows in which system each failure is classified, the electrical system or
mechanical system, when it is recorded in the abnormality record.
For details, see "Troubleshooting by failure code (Display of code)".
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WA470-7 40-133
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WA470-7 40-135
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WA470-7 40-137
40 Troubleshooting
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WA470-7 40-139
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WA470-7 40-141
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WA470-7 40-143
40 Troubleshooting
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40-144 WA470-7
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WA470-7 40-145
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40-146 WA470-7
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WA470-7 40-147
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WA470-7 40-149
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40-150 WA470-7
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WA470-7 40-151
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40-152 WA470-7
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WA470-7 40-153
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WA470-7 40-155
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WA470-7 40-157
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Troubleshooting by failure code (Display of code)
k Be sure to chock wheels. If you perform troubleshooting with parking brake released, depress foot
brake (two persons required for this work).
Action level Failure code Failure of Parking Brake Circuit
Failure
L03 2F00MA (Machine monitor system)
• Parking brake pressure switch remains off for 20 seconds during travel (parking brake is
Detail of applied).
failure (Monitor controller does not correctly recognize that parking brake pressure switch is ON
(parking brake is released)).
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • If machine is used as is, parking brake may be damaged.
machine
• When 24 V is applied to parking brake solenoid, parking brake is released.
• Method of reproducing failure code: Start engine and actual gear speed is other than
NEUTRAL.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
• Parking brake relay (L120) works as self-holding relay.
Related 1. When parking brake switch is operated, pin 5 and pin 6 of parking brake switch are
information connected with each other.
2. Parking brake relay is engaged and L120 works as self-holding relay.
3. When parking brake switch is set to Release position, pin 3 and pin 4 of parking brake
are connected with each other. Since L120 remains engaged, power is supplied to pin
4 of parking brake switch and then flows to L62 (6) pin of transmission controller.
4. If voltage of L62 (6) pin goes to 20 V or above, transmission controller drives parking
brake solenoid from L63 (18) pin (parking brake is released).
No. Cause Procedure, measuring location, criteria and remarks
Inappropriate operation • Check that parking brake switch is set to "Release" position.
1 of parking brake switch • Do not use parking brake while machine is travelling.
1. Turn starting switch to OFF position.
2. Interchange relay L120 with horn relay L119.
3. Start engine and drive machine.
Defective parking brake Does machine become Machine becomes Original relay L120 is
2 relay (L120) normal after parking normal. defective.
brake relay (L120) is
Machine does not Original relay L120 is
interchanged with relay
become normal. normal.
L119?
• When failure code [D1E6KA], [D1E6KB] or [D1E6KY] is displayed,
perform troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Interchange relay L133 with horn relay L119.
Defective auto-idle stop 3. Start engine and drive machine.
3 parking brake relay
L133 Does machine become Machine becomes Original relay L133 is
normal after parking normal. defective.
brake relay (L133) is Original relay L133 is
Machine does not
interchanged with relay normal.
become normal.
L119?
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WA470-7 40-159
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WA470-7 40-161
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WA470-7 40-163
40 Troubleshooting
Troubleshooting by failure code (Display of code)
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WA470-7 40-165
40 Troubleshooting
Troubleshooting by failure code (Display of code)
See "Failure code [879AKA] A/C Inner Sensor Open Circuit" in chapter 80 of "Others".
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See "Failure code [879AKB] A/C Inner Sensor Short Circuit" in chapter 80 of "Others".
WA470-7 40-167
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Troubleshooting by failure code (Display of code)
See "Failure code [879BKA] A/C Outer Sensor Open Circuit" in chapter 80 of "Others".
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See "Failure code [879BKB] A/C Outer Sensor Short Circuit" in chapter 80 of "Others".
WA470-7 40-169
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Troubleshooting by failure code (Display of code)
See "Failure code [879CKB] Ventilating Sensor Short Circuit" in chapter 80 of "Others".
a The ventilating sensor means the evaporator temperature sensor.
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See "Failure code [879CKB] Ventilating Sensor Short Circuit" in chapter 80 of "Others".
a The ventilating sensor means the evaporator temperature sensor.
WA470-7 40-171
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Troubleshooting by failure code (Display of code)
See "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit" in chapter 80 of "Others".
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WA470-7 40-173
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See "Failure code [879FMC] Air Mix Damper Abnormality" in chapter 80 of "Others".
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WA470-7 40-175
40 Troubleshooting
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WA470-7 40-177
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k Since temperature of KDPF and KDOC becomes 500 °C or higher, take care not to
get burn injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250°C, and
Related difference between these temperatures is approx. 10 °C. (KDOC inlet temperature >
information KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationery regeneration) is performed due to the
guidance of monitor displaying failure code A1U0N3 or A1U0N4, fuel dosing is disabled.
Accordingly, each temperature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to
approx. 250 to 400 °C.
• When active regeneration (manual stationary regeneration) except above is in progress,
KDOC inlet temperature is approx. 250 to 400 °C, and KDOC outlet temperature and
KDPF outlet temperature are approx. 450 to 550 °C.
• If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
WA470-7 40-179
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Troubleshooting by failure code (Display of code)
a Turn the starting switch ON and make sure that this failure code is not displayed.
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k Since the temperature of the KDPF and KDOC will become higher than 500 °C , take
care not to get burn injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301(V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 ( °C ))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401(V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 ( °C ))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201(V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 ( °C ))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature with
Related engine running at idle (without regenerating KDPF) are all approx. 100 to 250 °C and
information temperature differences among them are approx. 10 °C (KDOC inlet temperature >
KDOC outlet temperature> KDPF outlet temperature).
• When manual stationary regeneration is performed as an action taken for A1U0N3 or
A1U0N4, dosing fuel is not injected. Therefore, KDOC inlet, KDOC outlet, and KDPF
outlet temperatures will be around 250 to 400 °C .
• In other cases than the above, when active regeneration (manual stationary regeneration)
is in progress, the KDOC inlet temperature will be approx. 250 to 400 °C , and the KDOC
outlet temperature and KDPF outlet temperature will both be approx. 450 to 550 °C .
• If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
• KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
temperature sensor consolidating box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Perform manual stationary regeneration by following the instructions
Performing manual stationary on the monitor.
1
regeneration (to dry KDPF) If this failure code is cleared after regeneration is performed, repair is
complete.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
2 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
3 temperature sensor troubleshooting for it.
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a Turn the starting switch ON and make sure that this failure code and code [A1U0N3] are not displayed.
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WA470-7 40-183
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WA470-7 40-185
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Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors MCM1 A and E27, and connect T-adapters to each
defective contact of female side.
connector) Between MCM1 A (female) (69) and E27 (female)
Resistance (1) Max. 1 z
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WA470-7 40-187
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Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors and connect T-adapters to each female side.
defective contact of Between MCM1 A (female) (48) and R32 (female)
Max. 1 z
connector) Resistance (1)
Between R32 (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R32.
3. Turn starting switch to ON position.
Defective monitor
5 Radiator coolant level is
controller Max. 1 V
Voltage Between R32 (1) and (2) normal.
Radiator coolant level is
16 to 24V
low.
WA470-7 40-189
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WA470-7 40-191
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Failure code [CA115] Eng Ne and Bkup Speed Sens Error (PC400-CA115-400-A-Z0-A)
Action level Failure code Engine Ne and Bkup Speed Sensor Error
Failure
L04 CA115 (Engine controller system)
Detail of • Abnormality is detected in signal circuits of Ne and Bkup speed sensors at the same time.
failure
Action of • Stops engine.
controller
Problem on • Engine does not start (if engine is stopped).
machine • Engine stops (if engine is running).
Related • Method of reproducing failure code: Start engine.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective Ne speed sensor
1 Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
2 Perform troubleshooting for failure code [CA778].
system
If no failure is found by above checks, engine controller is defective.
3 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)
WA470-7 40-193
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Failure code [CA122] Chg Air Press Sensor High Error (PC400-CA122-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor High Error
Failure
L03 CA122 (Engine controller system)
Detail of • High voltage occurs in charge (boost) pressure sensor signal circuit.
failure
• Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Acceleration performance of engine drops.
machine • Engine output reduces.
• Signal voltage from charge (boost) pressure sensor can be checked with monitoring
function. (Code: 36501 (V))
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
Related
monitoring function. (Code: 36500 (kPa))
information
• Method of reproducing failure code: Turn starting switch to ON position.
• If sensor connector is disconnected, failure code [CA123] for "Low Error" is displayed
even in normal condition.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector PIM.
3. Turn starting switch to ON position.
If failure code changes from [CA122] to [CA123], charge (boost) pressure
sensor is defective.
Defective charge
3 (boost) pressure sensor • Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J1 or PIM.
3. Turn starting switch to ON position.
Between J1 (15) and (59), or between Sensor
Voltage 0.3 to 4.7 V
PIM (3) and (2) output
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and PIM, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of a To check open circuit in GND line
connector) Resistance Between J1 (female) (59) and PIM (female) (2) Max. 1 z
1. Turn starting switch to OFF position, then perform troubleshooting.
2. Disconnect connectors J1 and PIM, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between J1 (female) (15) and (60), or between PIM
Resistance (female) (3) and (1) Min. 1 Mz
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Failure code [CA123] Chg Air Press Sensor Low Error (PC400-CA123-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor Low Error
Failure
L03 CA123 (Engine controller system)
Detail of • Low voltage appears in boost pressure sensor signal circuit.
failure
• Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to
run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Acceleration performance of engine drops.
machine • Engine output lowers.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
using monitoring function (Code: 36501 (V)).
Related • Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor)
information can be checked by using monitoring function (Code: 36500 (kPa)).
• Method of reproducing failure code: Turn starting switch to ON position.
• If sensor connector is disconnected, this failure code is displayed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
2 system of boost 2. Disconnect connectors PIM and connect T-adapter to female side.
pressure sensor 3. Switch: ON
Voltage Between PIM (female) (1) and (2) Power input 4.75 to 5.25
V
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and PIM and connect T-adapters to each
female side.
3 (wire breakage or Between J1 (female) (60) and PIM (female) (1) Max. 1 z
defective contact of
connector) Resistance Between J1 (female) (15) and PIM (female) (3) Max. 1 z
Between J1 (female) (59) and PIM (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and PIM and connect T-adapters to either
Short circuit in wiring female side.
4
harness 3.
Between J1 (female) (15) and (59) or between PIM
Resistance (female) (3) and (2) Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position, then perform troubleshooting.
harness 2. Disconnect connectors J1 and PIM and connect T-adapter to either female
5 side.
(contact with ground
Between J1 (female) (15) or PIM (female) (3) and
circuit) Resistance ground Min. 1 Mz
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Failure code [CA135] Eng Oil Press Sensor High Error (PC400-CA135-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Sensor High Error
Failure
L01 CA135 (Engine controller system)
Detail of • High voltage occurs in engine oil pressure sensor signal circuit.
failure
Action of • Sets engine oil pressure to fixed value (250 kPa {2.5 kg/cm2}) and runs engine.
controller
Problem on
machine
• Signal voltage from engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 (V))
Related • Engine oil pressure sensed by engine oil pressure sensor can be checked with monitoring
information function. (Code: 37200 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective power supply
system of engine oil If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
pressure sensor for it first.
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Failure code [CA141] Eng Oil Press Sensor Low Error (PC400-CA141-400-A-Z0-A)
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Failure code [CA153] Chg Air Temp Sensor High Error (PC400-CA153-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor High Error
Failure
L03 CA153 (Engine controller system)
Detail of • High voltage appears in boost temperature sensor signal circuit.
failure
Action of • Takes it that boost temperature is at fixed temperature (70 °C ) and allows engine to run.
controller
Problem on • Engine does not start easily at low temperatures.
machine
• Signal voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
• Temperature sensed by boost temperature sensor can be checked with monitoring
function. (Code: 18500 (°C))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed as a T-adapter).
• This failure code is displayed if temperature sensor connector is disconnected.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z to 382 kz, regard
boost temperature sensor as normal.
291 to 382
-40 °C
Defective boost temperature kz
2
sensor -20 °C 85 to 109 kz
Between TIM (male) (A) and (B)
Resis- 0 °C 29 to 36 kz
tance a Boost temperature-Resistance 30 °C 7.3 to 8.8 kz
chariacteristic 60 °C 2.3 to 2.7 kz
90 °C 860 to 970 z
130 °C 280 to 320 z
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to female side.
Open or short circuit in wiring Between J1 (female) (5) and (59)
3
harness Resis- a Use Temperature-Resistance 280 z to 382
tance characteristics table for troubleshooting on kz
cause 2.
If no failure is found by above checks, engine controller is defective.
4 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)
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Failure code [CA154] Chg Air Temp Sensor Low Error (PC400-CA154-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor Low Error
Failure
L03 CA154 (Engine controller system)
Detail of • Low voltage appears in boost temperature sensor signal circuit.
failure
• Takes it that boost temperature is at fixed temperature (70 °C ) and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine does not start easily at low temperatures.
machine • Engine output lowers.
• Signal voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
• Temperature sensed by boost temperature sensor can be checked with monitoring
Related function. (Code: 18500 (°C))
information • Method of reproducing failure code: Turn starting switch to ON position.
• If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA153] for "High Error" is displayed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z to 382 kz, regard
boost temperature sensor as normal.
291 to 382
-40 °C
kz
Defective boost temperature -20 °C 85 to 109 kz
2 Between TIM (male) (A) and (B)
sensor 0 °C 29 to 36 kz
Resis- a Boost temperature-Resistance 30 °C 7.3 to 8.8 kz
tance chariacteristic 60 °C 2.3 to 2.7 kz
90 °C 860 to 970 z
130 °C 280 to 320 z
Between TIM (male) (B) and Whole
ground range Min. 1 Mz
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Failure code [CA239] Ne Speed Sens Supply Volt High Error (PC400-CA239-400-A-Z0-
A)
Action level Failure code Ne Speed Sensor Supply Voltage High Error
Failure
L01 CA239 (Engine controller system)
Detail of • High voltage appears in Ne speed sensor power supply (5 V) circuit.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (G) speed sensor is also defective).
machine • Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector NE.
3. Turn starting switch to ON position.
If this failure code is not displayed, disconnected sensor or engine wiring
2 Defective Ne speed sensor
harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than [CA239].
1. Turn starting switch to OFF position.
2. Disconnect connector J1.
3. Turn starting switch to ON position.
3 Defective wiring harness If this failure code disappears, wiring harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than [CA239].
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to male side.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
Voltage Between J1 (male) (36) and (37) 4.75 to 5.25
V
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Failure code [CA356] Mass Air Flow Sensor High Error (WA500_7-CA356-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor High Error
Failure
L03 CA356 (Engine controller system)
Detail of • High frequency appears in signal circuit of mass air flow sensor.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
Related • Mass air flow sensor and intake air temperature sensor are integrated.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective mass air flow 2. Disconnect connector E27.
3 sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code changes to [CA357], mass air flow sensor is
defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connector E27 and connect T-adapters to female side.
Defective sensor power
4 3. Turn starting switch to ON position.
supply system
Power Approx. 12
Voltage Between E27 (female) (2) and (3)
supply V
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J1 and E27, and connect T-adapters to each
5 (wire breakage or defective female side.
contact of connector)
a To check open circuit in GND line
Resis- Between J1 (female) (22) and E27 (female) (3)
Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to
female side of J1.
6 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Resis- Between J1 (female) (23) and each pin other
than pin (23) Min. 1 Mz
tance
If no failure is found by above checks, engine controller is defective.
7 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)
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Failure code [CA357] Mass Air Flow Sensor Low Error (WA500_7-CA357-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Low Error
Failure
L03 CA357 (Engine controller system)
Detail of • Low frequency appears in signal circuit of mass air flow sensor.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
• Mass air flow sensor and intake air temperature sensor are integrated.
Related • If sensor connector is disconnected, both this failure code and failure code [CA691] are
information displayed.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective mass air flow 2. Replace mass air flow sensor.
3 sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code does not appear, original mass air flow sensor is
defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connectorE27, and connect T-adapters to female side.
Defective sensor power
4 3. Turn starting switch to ON position.
supply system
Power Approx. 12
Voltage Between E27 (female) (2) and (3)
supply V
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to each
female side.
a If no failure is found by check on cause 4,
Open circuit in wiring harness this check is not required. Max. 1 z
5 (wire breakage or defective Between J1 (female) (21) and E27 (female) (2)
contact of connector) Resis-
tance a If no failure is found by check on cause 4,
this check is not required. Max. 1 z
Between J1 (female) (22) and E27 (female) (3)
Between J1 (female) (23) and E27 (female) (1) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J1 and E27, and connect T-adapters to
6 either female side.
(contact with ground circuit)
Resis- Between ground and J1 (female) (23) or E27
(female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to
female side of connector J1.
7 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Resis- Between J1 (female) (23) and each pin other
than pin (23) Min. 1 Mz
tance
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Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage : Output voltage: (pin 2 of connector PD and pin 51 of connector EC3)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Zone where both signals of IVS1 and IVS2 are OFF
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Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage : Output voltage: (pin 2 of connector PD and pin 51 of connector EC3)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Zone where both signals of IVS1 and IVS2 are OFF
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Failure code [CA515] Rail Press Sens Sup Volt High Error (PC400-CA515-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage High Error
Failure
L03 CA515 (Engine controller system)
Detail of • High voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
Action of • Limits engine output and allows engine to run.
controller • Limits the common rail pressure.
Problem on • Engine output lowers.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector PFUEL.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J2.
3. Turn starting switch to ON position.
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Hot short circuit in wiring
2. Disconnect connector PFUEL, and connect T-adapter to female side
4 harness
of connector.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between PFUEL (female) (1) and (3) 4.75 to 5.25
V
1. Turn starting switch to OFF position.
2. Disconnect connector J2, and connect T-adapter to male side.
5 Defective engine controller 3. Turn starting switch to ON position.
Voltage Between J2 (male) (31) and (21) 4.7 to 5.25
V
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Failure code [CA516] Rail Press Sens Sup Volt Low Error (PC400-CA516-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage Low Error
Failure
L03 CA516 (Engine controller system)
Detail of • Low voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
Action of • Limits engine output and allows engine to run.
controller • Limits the common rail pressure.
Problem on • Engine output lowers.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector PFUEL.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J2.
3. Turn starting switch to ON position.
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness
4 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
(contact with ground circuit) female side of either connector.
Resis- Between ground and J2 (female) (31) or
PFUEL (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
5 Short circuit in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
female side of either connector.
Resis- Between J2 (female) (21) and (31), or
between PFUEL (female) (1) and (2) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J2, and connect T-adapter to male side.
6 Defective engine controller 3. Turn starting switch to ON position.
Voltage Between J2 (male) (31) and (21) 4.7 to 5.25
V
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Note 2: Check, clean, and replace filters and strainers according to following procedure.
1. Gauze filter: Disassemble and check gauze filter. If clogged, clean it.
2. Upstream filter of gauze filter: If gauze filter is clogged, clean upstream filter, as well.
3. Fuel filter: If trouble is not solved by performing above steps 1) and 2), replace fuel filter.
Check sheet for fuel pressure low error
Model Work No.
Machine serial No. # Date of check / /
Engine SAA6D125E-6 Service meter h
Engine serial No. # Worker's name
No good
Good
A. Visual check
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No good
Good
B. Inspection with machine monitor
(02 = Abnormality record; 01 = Monitoring; 09 = Cylinder cutout mode operation)
No good
Good
value Measured
Code Item displayed Testing conditions ISO unit (Reference value
value)
Low idle r/min 800 (+50 / -0)
High idle r/min 2,170 (± 50)
01002 Engine speed Torque converter stall
r/min 1,710 (± 50)
(E-mode)
Torque converter stall
r/min 1,785 (± 50)
(P-mode)
Low idle % 0
31701 Throttle opening
High idle % 100
4 Last fuel injection
18600 quantity command Torque converter stall mg/st - - -
(in weight)
Last common rail
36200 Torque converter stall MPa -
pressure command
Common rail
36400 Torque converter stall MPa -
pressure
Low idle CA - - -
Last injection timing High idle - - -
36300 CA
command
Torque converter stall CA - - -
value Measured
Function Cutout cylinder Testing conditions ISO unit (Reference value
value)
No. 1 cylinder Low idle r/min - - -
5 No. 2 cylinder Low idle r/min - - -
Set
cylinder No. 3 cylinder Low idle r/min - - -
to be cut
out by No. 4 cylinder Low idle r/min - - -
cylinder.
No. 5 cylinder Low idle r/min - - -
No. 6 cylinder Low idle r/min - - -
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Standard
No good
Good
C. Check of fuel circuit value Measured
Testing conditions Unit
pressure (Reference value
value)
High idle or under load
Fuel pressure in low- equivalent to rated MPa {kg/ 0.15 to 0.3
6 pressure circuit operation (load by torque cm2} {1.5 to 3.0}
converter stall)
No good
Good
D. Check of strainers and filters
Standard
No good
Good
E. Check of leakage and value Measured
Testing conditions Unit
return rate (Reference value
value)
Engine operation
Leakage from pressure equivalent to rated
11 operation (with load by cc/min Max. 10
limiter
torque converter stall)
Torque converter stall at
1,600 rpm cc/min 960
Torque converter stall at
cc/min 1,020
1,700 rpm
Torque converter stall at Speed:
12 Return rate from injector 1,800 rpm cc/min 1,080
Return rate:
Torque converter stall at
cc/min 1,140
1,900 rpm
Torque converter stall at
cc/min 1,200
2,000 rpm
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• The Ne speed sensor detects area (A) where holes (H) are not drilled through flywheel (1), and the engine
controller calculates the engine speed and signal phase.
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Failure code [CA691] Intake Air Temp Sens High Error (WA500_7-CA691-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor High Error
Failure
L01 CA691 (Engine controller system)
Detail of • High voltage appears in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake air temperature is at fixed value (25 °C) and allows engine to run.
controller
Problem on
machine
• Mass air flow sensor and intake air temperature sensor are integrated.
• Signal voltage from intake air temperature sensor can be checked with monitoring
function. (Code: 18401 (V))
Related • Temperature sensed by intake air temperature sensor can be checked with monitoring
information function. (Code: 18400 (°C))
• If sensor connector is disconnected, this failure code is displayed together with failure
code [CA357].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector E27 and connect T-adapters to male side.
-30°C 25 to 28 kz
Defective intake air Between E27 (male) (3) and (4) 0°C 5.5 to 6.1 kz
2 temperature sensor 25°C 1.9 to 2.1 kz
(internal defect) Resis- a Intake air temperature-
tance Resistance characteristics 40°C 1.1 to 1.2 kz
100°C 180 to 185 z
Between E27 (male) (3) and Whole
ground (sensor body) range Min. 1 Mz
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Failure code [CA692] Intake Air Temp Sens Low Error (WA500_7-CA692-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor Low Error
Failure
L01 CA692 (Engine controller system)
Detail of • Low voltage appears in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake air temperature is at fixed value (25 °C) and allows engine to run.
controller
Problem on
machine
• Mass air flow sensor and intake air temperature sensor are integrated.
• Signal voltage from intake air temperature sensor can be checked with monitoring
Related function. (Code: 18401 (V))
information • Temperature sensed by intake air temperature sensor can be checked with monitoring
function. (Code: 18400 (°C))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector E27.
3. Turn starting switch to ON position.
If this failure code changes to failure code [CA691], intake air
temperature sensor is defective.
• Reference
Defective intake air 1. Turn starting switch to OFF position.
2 temperature sensor 2. Disconnect connector E27 and connect T-adapters to male side.
(internal defect) -30°C 25 to 28 kz
Between E27 (male) (3) and (4) 0°C 5.5 to 6.1 kz
25°C 1.9 to 2.1 kz
Resis- a Intake air temperature-
tance Resistance characteristics 40°C 1.1 to 1.2 kz
100°C 180 to 185 z
Between E27 (male) (3) and Whole
ground (sensor body) range Min. 1 Mz
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Failure code [CA697] ECM Internal Temp Sensor High Error (PC400-CA697-400-A-Z0-
A)
Action level Failure code ECM Internal Temperature Sensor High Error
Failure
L01 CA697 (Engine controller system)
Detail of • High voltage appears in engine controller internal temperature sensor signal circuit.
failure
Action of • None in particular.
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by
Related using monitoring function (Code: 18900(°C)).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1 Improper usage of controller Check if the controller has been used in high temperature environments.
If no failure is found by above checks, engine controller is defective.
2 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)
WA470-7 40-283
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Failure code [CA698] ECM Int Temp Sensor Low Error (PC400-CA698-400-A-Z0-A)
Action level Failure code ECM Internal Temperature Sensor Low Error
Failure
L01 CA698 (Engine controller system)
Detail of • Low voltage appears in engine controller internal temperature sensor signal circuit.
failure
Action of • None in particular.
controller
Problem on
machine
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Failure code [CA731] Eng Bkup Speed Sens Phase Error (PC400-CA731-400-A-Z0-A)
Action level Failure code Engine Bkup Speed Sensor Phase Error
Failure
L01 CA731 (Engine controller system)
• Engine controller receives signals from engine Bkup sensor, and detects a signal phase
Detail of error.
failure (The signal is out of phase when compared with signals sent from Ne speed sensor.)
Action of • Controls engine by using signals from engine Ne speed sensor.
controller
Problem on • Running engine stops (when Ne speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Ne speed sensor is also defective).
• Method of reproducing failure code: Start engine.
Related
information a The fuel supply pump must also be replaced during replacement of Bkup speed sensor.
(See Disassembly and assembly, "Removal and installation of fuel supply pump".)
No. Cause Procedure, measuring location, criteria and remarks
Defective engine Ne speed Engine Ne speed sensor may be defective. Perform troubleshooting for
1 failure code [CA689].
sensor circuit
Defective engine Bkup speed Engine Bkup speed sensor may be defective. Perform troubleshooting
2 for failure code [CA778].
sensor circuit
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k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
General • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
information engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approximately 250 to 400°C, and KDOC outlet temperature and KDPF
outlet temperature are approximately 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
repair.
WA470-7 40-289
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Defective wiring 1. See descriptions of wiring harness and connectors in "c: Electrical
3 equipment" in "Checks before troubleshooting" of "General information on
harness connector
troubleshooting", and check it and repair as needed.
1. Turn starting switch to ON position.
2. Monitor signal voltages from KDOC inlet temperature sensor and KDOC
outlet temperature sensor, and note signal voltages from respective
temperature sensors in initial condition (see Related information).
3. Turn starting switch to OFF position.
4. Disconnect either connector TEMP1 or TEMP2.
Short circuit in wiring 5. Turn starting switch to ON position.
4 6. Monitor signal voltages from KDOC inlet temperature sensor and KDOC
harness
outlet temperature sensor, and note second signal voltages from
respective temperature sensors (see Related information).
If second signal voltages sensed by KDOC inlet temperature sensor and
KDOC outlet temperature sensor do not change notably (almost same as first
signal voltages), check wiring harness for short circuit (troubleshooting for
failure codes [CA3313] and [CA3316]).
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k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C)
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration (normal) is in progress, KDOC inlet temperature is
approximately 250 to 400°C, and KDOC outlet temperature and KDPF outlet temperature
are approximately 450 to 550°C.
Related • When manual stationary regeneration without injecting dosing fuel (KDOC drying) is in
information progress, KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature are all approximately 250 to 400°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• Procedure of performing manual stationary regeneration from Regeneration for Service.
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from "Regeneration for Service".
1. Start the engine.
2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, select "Diagnostic Tests", open "02 Regeneration
for Service", and then perform "Manual Stationary Regeneration (manual stationary
regeneration will be completed in approximately 40 minutes).
a Failure code [CA2637] may be displayed at the same time, however, perform
troubleshooting for this failure code [CA1691].
• Method of reproducing failure code:
When KDOC is changed, there is no need to check completion of repair.
When KDOC is not changed, start engine and turn manual stationary regeneration switch
ON. (See cause 6.)
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1. Remove KDPF.
Defective KDOC 2. Remove KDOC.
4 (dirty or cracked or damaged 3. Blow air from KDOC outlet side to clean ceramic surfaces inside
KDOC surface) KDOC.
4. Check ceramic inside KDOC for cracks.
If cracks are found in KDOC, KDOC is defective (replace KDOC).
a Perform the following regardless whether KDOC is replaced or not.
1. Install KDOC and KDPF.
2. Turn starting switch to ON position.
3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
a When reset after KDOC change is performed, failure codes
5 Reset after KDOC change [CA1691] and [CA2637] will not be displayed. At that time, remedy of
not injecting dosing fuel when the failure code is displayed is
released.
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
manual stationary regeneration.
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Action level Failure code KDPF Delta Pressure Sensor High Error
Failure
L03 CA1879 (Engine controller system)
Detail of • High voltage appears in signal circuit of KDPF delta pressure sensor.
failure
• Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
Action of run engine.)
controller • Closes EGR valve and KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
k Since KDPF is heated to 500°C or above, take care not to get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1695] is not displayed but failure code [CA3133] is on screen, GND
Related circuit probably has open circuit (defective contact of connector).
information • Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.
Defective KDPF delta If failure code changes to [CA1881], KDPF delta pressure sensor is
3 pressure sensor defective.
a If this failure code remains displayed, wiring harness or engine
controller is defective.
a Ignore other displayed failure codes.
a If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and E25, and connect T-adapters to
4 each female side.
(wire breakage or defective
contact of connector) a To check open circuit in GND line
Resis- Between EC3 (female) (43) and E25 (female)
(1) Max. 1 z
tance
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Action level Failure code KDPF Delta Pressure Sensor Low Error
Failure
L03 CA1881 (Engine controller system)
Detail of • Low voltage appears in signal circuit of KDPF delta pressure sensor.
failure
• Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
Action of run engine.)
controller • Closes EGR valve and open KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
k Since KDPF is heated to 500°C or above, take care not to get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1696] is not displayed but failure code [CA3134] is on screen, sensor
connector is probably disconnected or 5 V circuit probably has open circuit (defective
Related contact of connector).
information • This failure code appears if sensor connector is disconnected.
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25
V
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
each female side.
a If no failure is found by check on cause 2,
this check is not required. Max. 1 z
Open circuit in wiring harness Between EC3 (female) (43) and E25 (female)
3 (wire breakage or defective (1)
contact of connector) Resis-
a If no failure is found by check on cause 2,
tance
this check is not required. Max. 1 z
Between EC3 (female) (52) and E25 (female)
(4)
Between EC3 (female) (55) and E25 (female)
(2) Max. 1 z
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Action level Failure code KDPF Delta Pressure Sensor In Range Error
Failure
L03 CA1883 (Engine controller system)
Detail of • Signal voltage from KDPF delta pressure sensor is out of range. (Signal voltage from
failure sensor is within operating range.)
• Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
run engine.)
Action of • Closes EGR valve and open KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
a You can cancel above measures by "turning starting switch to OFF position and then to
ON position" after failure code is generated.
Problem on • Engine output decreases.
machine
k Since KDPF is heated to 500°C or above, take care not to get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
Related function. (Code: 47400 (°C))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• Oil temperature sensed by torque converter oil temperature sensor can be checked with
monitoring function. (Code: 30100 T/C oil temperature)
a Use "Short-circuit connector: 799T-601-4611".
• As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute minimum before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and fixing
Machine O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after fixing trouble.
A. Identification of cause and fixing
No. Cause Procedure, measuring location, criteria and remarks
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power supply 1. Turn starting switch to OFF position.
1 system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. See descriptions of wiring harness and connectors in "c: Electrical
2 Defective harness connector equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it and fix trouble as
needed.
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k Place machine on a flat ground, turn parking brake switch to ON position, and chock wheels.
1. Turn starting switch to ON position and leave it in that position for 1 minute. (In order to allow engine
controller to determine drift of voltage when starting switch is turned to ON position.)
2. Turn starting switch from OFF position to ON position.
3. Start engine and run it at low idle for approximately 1 minute.
4. After warm-up operation, perform <torque converter stall operation> as described below.
<Torque converter stall operation>
5. Set transmission cut-off switch to "OFF" position and depress left brake pedal securely.
6. Set torque converter lockup switch (if equipped) to "OFF" position.
7. Set transmission shift mode selector switch to "MANUAL".
8. While keeping directional lever or directional selector switch in "N" (NEUTRAL) position, set gear shift
lever or gear shift switch to "4th" gear speed.
9. Release parking brake.
10.While depressing brake pedal, set directional lever or directional selector switch to "F (forward)" or "R
(reverse)" position.
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k Since KDOC and KDPF are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
Related • Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
information function. (Code: 47100 (kPa))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When the active regeneration (the manual stationary regeneration) is in progress, KDOC
inlet temperature is approximately 250 to 400°C, and KDOC outlet temperature and KDPF
outlet temperature are approximately 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
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a Time required for the manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
• If soot accumulation is level 4: approximately 40 minutes to 1 hour
• If soot accumulation is level 5: approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: approximately 1 to 3 hours
• If soot accumulation is level 8: The manual stationary regeneration can not be performed.
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that leads to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
a If failure code [CA1922] has been displayed originally, it changes to [CA1921] during
troubleshooting process of [CA1922]. In such case, refer to failure code [CA1922].
• Method of reproducing failure code: Turn starting switch to the ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Check if the regeneration stop button is pressed down from the
machine monitor.
a If the regeneration stop button is pressed down, release it.
2. Start the engine.
3. Make sure that machine is in safe condition.
4. Perform manual stationary regeneration from user mode.
a When the manual stationary regeneration is finished correctly, the
Excessive KDPF (KCSF) repair is completed.
1
soot accumulation level
a If the regeneration does not complete within 3 hours, perform the
troubleshooting of [CA2639].
a Check that failure code is not displayed after manual stationary
regeneration is completed.
a If failure code [CA1922] or [CA2639] is displayed after manual
stationary regeneration is completed, proceed to checks on
cause 2.
a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
a For check of the exhaust gas color, see "30 Testing and adjusting",
"Testing exhaust gas color".
2 Unusual exhaust gas color a When checking the exhaust gas color, perform the "Regeneration
Disable" from the machine monitor.
1. Rapidly accelerate engine from low idle to high idle 2 times, and then
keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
clogged in a short time".
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k Since KDOC and KDPF are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
Related • Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
information function. (Code: 47100 (kPa))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When the active regeneration (the manual stationary regeneration) is in progress, KDOC
inlet temperature is approximately 250 to 400°C, and KDOC outlet temperature and KDPF
outlet temperature are approximately 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
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a Time required for the manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
• If soot accumulation is level 4: approximately 40 minutes to 1 hour
• If soot accumulation is level 5: approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: approximately 1 to 3 hours
• If soot accumulation is level 8: The manual stationary regeneration can not be performed.
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that lead to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
• Procedure of performing the manual stationary regeneration from the "Regeneration for
Service".
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from the "Regeneration for Service".
1. Start the engine.
2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"Regeneration for Service", and then perform the "Manual Stationary Regeneration".
a Resetting after KDPF cleaning
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Cleaning" (reset after KDPF cleaning).
a Resetting after KDPF change
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Change" (resetting after KDPF change).
a When KCSF in KDPF is changed, always perform resetting procedures for KDPF cleaning
and KDPF change, and then perform the "Manual Stationary Regeneration" from the
"Regeneration for Service" to eliminate moisture from KCSF.
• Method of reproducing failure code: Turn starting switch to the ON position.
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k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • If failure code [CA2732] is also displayed, the ground (GND) leads may be open.
• This failure code appears if sensor connector is disconnected.
• See failure code [CA1925].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
Defective dosing fuel 2. Disconnect connector SOV1, and connect T-adapter to male side of
2 solenoid valve 1 (shut-off connector.
valve) Resis- Between SOV1 (male) (2) and (1)
4 to 6 z
tance
1. Turn starting switch to OFF position.
Open or short circuit in wiring 2. Disconnect connector J2 and connect T-adapters to female side.
3
harness Resis- Between J2 (female) (9) and (18)
4 to 6 z
tance a The resistance is the same as above.
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SOV1, and connect T-adapter to each
Open circuit in wiring harness female side of connectors.
4 (wire breakage or defective a To check open circuit in GND line
contact of connector)
Between J2 (female) (9) and SOV1 (female)
Max. 1 z
Resis- (1)
tance Between J2 (female) (18) and SOV1 (female)
(2) Max. 1 z
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k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • If sensor connector is disconnected, failure code [CA1923] appears.
• See failure code [CA1925].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
Defective fuel doser solenoid 2. Disconnect connector SOV1, and connect T-adapter to male side of
valve 1 connector.
2 Between SOV1 (male) (2) and (1) 4 to 6 z
(shut-off valve) Resis-
Between SOV1 (male) (1) and ground (SOV
tance Min. 1 Mz
body)
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring
3 Between J2 (female) (9) and (18)
harness Resis-
a The resistance is the same as that of shut- 4 to 6 z
tance
off valve.
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
4 harness 2. Disconnect connectors J2 and SOV1, and connect T-adapter to
(contact with ground circuit) female side of either connector.
Resis- Between ground and J2 (female) (9) or SOV1
(female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SOV1, and connect T-adapter to
female side of connector J2.
a Check by using multimeter in continuity mode.
5 Short circuit in wiring harness
No
continuity
Between J2 (female) (9) and each pin other
Continuity (No sound
than pin (9)
is heard)
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k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
• In this failure code, the dosing fuel valve 1 (shut-off valve) is determined defective from
the fuel pressure change caused by the operation of solenoid valve.
• Therefore, the pressure check by fuel pressure sensor is required.
• When the starting switch is turned to ON position, the fuel pressure is checked by the
engine controller.
Related • Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
information (Code: 47600 (V))
• Pressure detected by dosing fuel pressure sensor can be checked with monitoring
function. (Code: 47601 (kPa))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• Method of reproducing failure code: Start the engine (and observe for 3 minutes).
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approx. 3 minutes, repair is completed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1927] or [CA1928] is also displayed, perform
troubleshooting for [CA1927] or [CA1928] first.
1. Turn starting switch to OFF position.
Defective dosing fuel 2. Disconnect fuel supply line (2) from fuel doser (1).
2 pressure sensor 3. Turn starting switch to ON position.
If the dosing fuel pressure is clearly different from ambient pressure, the
dosing fuel pressure sensor is defective (see "Related information").
a The dosing fuel pressure must be equal to the ambient pressure.
1. Turn starting switch to OFF position.
2. Disconnect fuel supply line (2) from fuel doser (1).
3. Disconnect connector SOV1.
4. Connect the disconnected SOV1 connector to a new SOV connector
socket.
Defective dosing fuel shut-off a If connector SOV1 is open, failure code [CA1923] is displayed
3
valve and the pressure test (which checks the fuel dosing system) is
not carried out. Also, the electric fuel pump is not driven.
5. Turn starting switch to ON position.
6. Start engine.
If fuel leaks from the fuel connector of fuel supply line (2), dosing fuel
solenoid valve 1 (shut-off valve) (3) is defective.
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Failure code [CA1927] Dosing Fuel Press Sens High Error (PC400-CA1927-400-A-Z0-A)
Action level Failure code Dosing Fuel Pressure Sensor High Error
Failure
L01 CA1927 (Engine controller system)
Detail of • Signal voltage from doser fuel pressure sensor indicates a value higher than the
failure threshold.
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.
k Since the temperature of the exhaust connector and KDPF will become higher than
500 °C , take care not to get burn injury.
Related • Signal voltage from the doser fuel pressure sensor can be checked by using monitoring
information function. (Code: 47600(V))
• The pressure sensed by the doser fuel pressure sensor can be checked by using
monitoring function. (Code: 47601 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position (observe for one
minute) (since this is L01, check on the abnormality record screen).
No. Cause Procedure, measuring location, criteria and remarks
1. Perform checks referring to harness and connecter related
descriptions in "c: Electrical equipment" of "Checks before
Defective wiring harness troubleshooting" in "General information on troubleshooting".
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA352] or [CA386] is displayed, perform troubleshooting
for it first.
1. Turn starting switch to OFF position.
Doser fuel pressure sensor
2 power supply error 2. Disconnect connector PDOSER and connect T-adapter to female
side.
3. Turn starting switch to ON position.
Voltage Between PDOSER (female) (1) and (2) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connector PDOSER.
3. Turn starting switch to ON position.
Defective doser fuel pressure If failure code changes from [CA1927] to [CA1928], doser fuel pressure
3
sensor sensor is defective.
• Carry out troubleshooting for cause 1 again.
• If failure code [CA1927] does not changes to [CA1928], the wiring
harness or engine controller is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and PDOSER, and connect T-adapters to
Open circuit in wiring each female side.
harness a To check for open circuit in GND line
4
(wire breakage or defective
contact of connector) a If no failure is found by check on cause 2,
Resis- this check is not required. Max. 1 z
tance Between J2 (female) (47) and PDOSER
(female) (2)
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Failure code [CA1928] Dosing Fuel Press Sens Low Error (PC400-CA1928-400-A-Z0-A)
Action level Failure code Dosing Fuel Pressure Sensor Low Error
Failure
L01 CA1928 (Engine controller system)
Detail of • Signal voltage from doser fuel pressure sensor indicates a value lower than the threshold.
failure
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.
k Since the temperature of the exhaust connector and KDPF will become higher than
500 °C , take care not to get burn injury.
• Signal voltage from the doser fuel pressure sensor can be checked by using monitoring
Related function. (Code: 47600(V))
information • The pressure sensed by the doser fuel pressure sensor can be checked by using
monitoring function. (Code: 47601 (kPa))
• This failure code is displayed if the sensor connector is disconnected.
• Method of reproducing failure code: Turn starting switch to ON position (observe for one
minute) (since this is L01, check on the abnormality record screen).
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA352] or [CA386] is displayed, perform troubleshooting
for it first.
Doser fuel pressure sensor 1. Turn starting switch to OFF position.
2 2. Disconnect connector PDOSER and connect T-adapter to female
power supply error
side.
3. Turn starting switch to ON position.
Voltage Between PDOSER (female) (1) and (2) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
Defective doser fuel pressure 2. Disconnect connector PDOSER.
3 3. Turn starting switch to ON position.
sensor
Voltage Between PDOSER (3) and (2) 0.5 to 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and PDOSER, and connect T-adapters to
each female side.
a If no failure is found by check on cause 2,
Open circuit in wiring this check is not required. Max. 1 z
harness Between J2 (female) (30) and PDOSER
4 (female) (1)
(wire breakage or defective
contact of connector) Resis-
a If no failure is found by check on cause 2,
tance
this check is not required. Max. 1 z
Between J2 (female) (47) and PDOSER
(female) (2)
Between J2 (female) (36) and PDOSER
(female) (3) Max. 1 z
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k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47600 (V))
Related • Pressure detected by dosing fuel pressure sensor can be checked with monitoring
information function. (Code: 47601 (kPa))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• Method of reproducing failure code: Start the engine (and observe for 3 minutes).
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approx. 3 minutes, repair is completed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective dosing fuel
If failure code [CA1923], [CA1924] or [CA1925] is also displayed,
2 solenoid valve 1 (shut-off
perform troubleshooting for [CA1923], [CA1924] or [CA1925] first.
valve)
Defective dosing fuel If failure code [CA2732] or [CA2733] is also displayed, perform
3 solenoid valve 2 (drain valve) troubleshooting for [CA2732] or [CA2733] first.
Defective dosing fuel If failure code [CA1927] or [CA1928] is also displayed, perform
4 pressure sensor troubleshooting for [CA1927] or [CA1928] first.
If failure code [CA559] is also displayed, perform troubleshooting for
5 Defective fuel supply pump
[CA559] first.
If failure code [CA2265] or [CA2266] is also displayed, perform
troubleshooting for [CA2265] or [CA2266] first.
1. Turn starting switch to OFF position.
2. Loosen the joint bolt (JB) of fuel tube.
Defective electric fuel feed 3. Tilt the switch for the fuel feed pump to ON position while starting
6 pump switch is in OFF position.
(Be careful since fuel may spurt out.)
When completing the check, turn the starting switch to ON position or
tilt the switch for the fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB), the electric fuel feed pump is
defective.
7 Clogging of fuel filter Check fuel filter for clogging.
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k Since exhaust connector and KDPF are heated to 500 °C or above, take care not to
get burn injury.
• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
Related (Code: 47600 (V))
information • Pressure detected by dosing fuel pressure sensor can be checked with monitoring
function. (Code: 47601 (kPa))
• This failure code appears if sensor connector is disconnected.
• Method of reproducing failure code: Turn starting switch to ON position (observe for 1
minute).
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector DOSER, and connect T-adapter to male side
of connector.
2 Defective fuel doser (injector)
Between DOSER (male) (1) and (2) 0.5 to 2 z
Resis-
Between DOSER (male) (1) and ground (fuel
tance Min. 1 Mz
doser body)
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring Between J2 (female) (50) and (60)
3
harness Resis-
a The resistance is the same as fuel doser 0.5 to 2 z
tance
(injector).
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J2 and DOSER, and connect T-adapters to
4 (wire breakage or defective each female side.
contact of connector) Between J2 (female) (50) and DOSER (female)
Max. 1 z
Resis- (1)
tance Between J2 (female) (60) and DOSER (female)
(2) Max. 1 z
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k Since KDPF is heated to 500°C or above, take care not to get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
Related function. (Code: 47300 (°C))
information • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute minimum before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and repair
Machine O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after repair trouble.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDPF delta If failure code [CA1879], [CA1881], or [CA1883] is displayed, perform
1 pressure sensor troubleshooting for [CA1879], [CA1881], or [CA1883] first.
1. Turn starting switch to OFF position once, and then turn it to ON
position.
2. Check whether failure codes other than [CA1993] are generated.
3. Start engine and accelerate it suddenly from low idle to full speed 2
times, then run it at high idle for 5 seconds. During above operation,
check exhaust gas color at exhaust pipe when engine accelerates
suddenly and runs at high idle.
2 KCSF abnormality 1
4. If black smoke is exhausted from exhaust pipe in above step 3,
KCSF is abnormal. Check whether KCSF is installed. If yes, check
KCSF for damage and contamination by foreign substances, and fix
trouble as needed.
a If black smoke is not exhausted, proceed to checks on causes 3 and
after.
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k Place machine on a level ground and set parking brake lever to LOCK position.
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Failure code [CA2185] Throt Sensor Sup Volt High Error (WA380_7-CA2185-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
L03 CA2185 (Engine controller system)
Detail of • High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
failure
Action of • Sets throttle position at 0% with accelerator pedal released and at 50 % with accelerator
controller pedal depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector PD and turn starting switch to ON position.
Defective throttle sensor If this failure code disappears, throttle sensor is defective.
2 (accelerator pedal)
a Other failure codes are also displayed. They are generated because
of disconnection of connector. Ignore failure codes other than
[CA2185].
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and PD, and connect T-adapters to
female side of EC3.
3 Short circuit in wiring harness Between EC3 (female) (42) and each pin
Min. 1 Mz
Resis- other than pin (42)
tance Between EC3 (female) (42) and EC3
(female) (1) Min. 1 Mz
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Failure code [CA2186] Throt Sensor Sup Volt Low Error (WA380_7-CA2186-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
L03 CA2186 (Engine controller system)
Detail of • Low voltage appears in throttle sensor power supply circuit.
failure
Action of • Sets throttle position at 0% with accelerator pedal released and at 50 % with accelerator
controller pedal depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector PD and turn starting switch to ON position.
Defective throttle sensor If this failure code disappears, throttle sensor is defective.
2 (accelerator pedal)
a Other failure codes are also displayed. They are generated because
of disconnection of connector. Ignore failure codes other than
[CA2186].
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors EC3 and PD, and connect T-adapters to
3 harness either female side.
(contact with ground circuit) Resis- Between ground and EC3 (female) (42) or
PD (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and PD, and connect T-adapters to
4 Short circuit in wiring harness female side of EC3.
Resis- Between EC3 (female) (42) and each pin
other than pin (42) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and connect T-adapters to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness
disconnected.
Voltage Between EC3 (42) and (41) 4.75 to 5.25 V
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Failure code [CA2271] EGR Valve Pos Sens High Error (PC400-CA2271-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor High Error
Failure
L03 CA2271 (Engine controller system)
Detail of • High voltage appears in EGR valve lift sensor signal circuit.
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
• Signal voltage from EGR valve lift sensor can be checked by using monitoring function.
(Code: 18100 (mm))
Related • EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using
information monitoring function. (Code: 18101 (V))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
Defective sensor power If failure code [CA352] or [CA386] is also displayed, perform
2 supply system troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective EGR valve lift 2. Disconnect connector SEGR.
3 sensor 3. Turn starting switch to ON position (with connector SEGR
(internal defect) disconnected).
If failure code changes from [CA2271] to [CA2272], sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SEGR, and connect T-adapters to
Open circuit in wiring harness each female side.
4 (wire breakage or defective
contact of connector) a To check for open circuit in GND line
Resis- Between J2 (female) (47) and SEGR (female)
(2) Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SEGR, and connect T-adapter to
Short circuit in wiring harness either female side.
5
Between J2 (female) (30) and (59), between
Resis- SEGR (female) (1) and (3), or between SEGR
Min. 1 Mz
tance (female) (1) and (4)
1. Turn starting switch to OFF position.
Hot short circuit in harness 2. Disconnect connector SEGR and connect T-adapter to female side.
6 3. Turn starting switch to ON position (with connector SEGR
(contact with 24 V circuit) disconnected).
Voltage Between SEGR (female) (3) or (4) and (2) Max. 1 V
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J2.
3. Turn starting switch to ON position.
Voltage Between J2 (59) and (47) 1.0 to 4.0
V
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Failure code [CA2272] EGR Valve Pos Sens Low Error (PC400-CA2272-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor Low Error
Failure
L03 CA2272 (Engine controller system)
Detail of • Low voltage appears in EGR valve lift sensor signal circuit.
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
• Signal voltage from EGR valve lift sensor can be checked by using monitoring function.
(Code: 18101 (V))
Related • EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using
information monitoring function. (Code: 18100 (mm))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA352] or [CA386] is also displayed, perform
troubleshooting for it first.
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Failure code [CA2555] Grid Htr Relay Volt Low Error (WA470_7-CA2555-400-A-Z0-A)
Action level Failure code Grid Heater Relay Voltage Low Error
Failure
L01 CA2555 (Engine controller system)
Detail of • Open circuit is in preheat relay drive circuit (primary circuit).
failure
Action of • None in particular
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to the ON position (Engine
General coolant temperature: Max. -5 °C).
information • Troubleshooting of this failure code covers circuits from engine controller to primary circuit
(coil) of preheat relay L125.
• For troubleshooting of secondary circuit of heater relay and preheat relay L125, see E-2 in
E-mode troubleshooting.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following troubleshooting.
1. Turn starting switch to OFF position.
Defective preheat
2 2. Disconnect relay L125 and connect T-adapter to male side.
relay L125
Resistance Between L125 (male) (1) and (2) 200 to 400 z
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connectors EC3 and connect T-adapter to female side.
3 wiring harness Between EC3 (female) (4) and ground
Resistance 200 to 400 z
a To measure coil resistance of relay L125
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connector EC3 and relay L125, and connect T-adapters to each
4
harness female side.
Between EC3 (female) (4) and L125 (female) (1) Max. 1 z
Resistance
Between L125 (female) (2) and ground Max. 1 z
Defective engine If no failure is found by above checks, engine controller is defective.
5
controller (Since this is an internal defect, troubleshooting cannot be performed.)
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Failure code [CA2556] Grid Htr Relay Volt High Error (WA470_7-CA2556-400-A-Z0-A)
Action level Failure code Grid Heater Relay Voltage High Error
Failure
L01 CA2556 (Engine controller system)
Detail of • Short circuit is in preheat relay drive circuit (primary circuit).
failure
Action of • None in particular
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to the ON position (Engine coolant
General temperature: Max. -5 °C).
information • Troubleshooting of this failure code covers circuits from engine controller to primary circuit
(coil) of preheat relay L125.
• For troubleshooting of secondary circuit of heater relay and preheat relay L125, see E-2 in
E-mode troubleshooting.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following troubleshooting.
1. Turn starting switch to OFF position.
Defective preheat
2 2. Disconnect relay L125 and connect T-adapter to male side.
relay L125
Resistance Between L125 (male) (1) and (2) 200 to 400 z
1. Turn starting switch to OFF position.
2. Disconnect connector EC3 and relay L125, and connect T-adapter to either
Ground fault in wiring
3 female side.
harness
Between ground and EC3 (female) (4) or L125
Resistance (female) (1) Min. 1 Mz
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a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• Procedure of performing manual stationary regeneration from Regeneration for Service.
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from "Regeneration for Service".
Related 1. Start the engine.
information 2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"02 Regeneration for service", and then perform the "Manual Stationary
Regeneration".
• If the KDOC efficiency is still low, this failure code [CA2637] may be displayed repeatedly
and failure code [CA1691] indicating the poor regeneration may be displayed.
<How to clear failure code>
• Start the engine and perform the warm-up operation, then operate the machine under
normal conditions for approximately 3 hours.
(If the exhaust gas temperature is high, this operation time can be reduced.)
No. Cause Procedure, measuring location, criteria and remarks
1 Defective KVGT If failure code [CA238*] is displayed, troubleshoot for it first.
If failure code [CA227*], [CA23**] or others is displayed, troubleshoot for
2 Defective EGR valve
it first.
1. Remove turbocharger exhaust connector.
Defective turbocharger 2. Check for oil or fuel inside turbocharger exhaust connector.
3
exhaust connector • If contaminated, troubleshoot for failure codes [CA227*], [CA23**],
etc., relating to the EGR valve and KVGT.
Defective exhaust connector Check exhaust system between turbocharger and KDPF for damage of
4 and ducts connected to the connector and ducts, and for loose connection.
KDPF
1. Rapidly accelerate engine from low idle to high idle two times, and
then keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when running the engine at
high idle, troubleshoot for "S-9 KDPF gets clogged in a short time".
5 Unusual exhaust gas color
a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.
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a Operate the machine approximately 3 hours and check that this failure code is not displayed.
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k Since KDOC and KDPF are heated to 500°C or above, take care not to get burn
injury.
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a Time required for manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
• If soot accumulation is level 4: Approx. 40 minutes to 1 hour
• If soot accumulation is level 5: Approx. 1 to 2 hours
• If soot accumulation is level 6 or 7: Approx. 1 to 3 hours
Related • If soot accumulation is level 8: The manual stationary regeneration can not be performed.
information
a If this failure code is still displayed after several hours have passed after manual
stationary regeneration, perform following troubleshooting procedures.
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Check if the regeneration stop button is pressed down from the
machine monitor.
If the regeneration stop button is pressed down, release it.
2. Turn starting switch to the ON position.
Increase of soot 3. Make sure that machine is in safe condition.
1 accumulation due to 4. Start the engine, and perform the manual stationary regeneration
"Regeneration Disable" from user mode.
a When the manual stationary regeneration is finished correctly, the
repair is completed.
a If the regeneration does not complete within 3 hours, proceed to
checks on cause 2 and after.
• If there is a significant difference between KDOC inlet temperature
Defective KDOC inlet and KDOC outlet temperature when KDPF is completely cool or
2 temperature sensor engine running at idle (not regenerating), replace KDOC inlet
temperature sensor.
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged after
3 Defective KVGT performing regeneration for service, KVGT is defective.
(The time required for manual stationary regeneration depends on the
accumulated soot level. See related information.)
Defective KDPF (KDOC, 1. Perform the troubleshooting "S-22 Active regeneration takes time" of
4 KCSF) S mode.
a If failure code [CA2639] is displayed after the manual stationary
regeneration is completed, perform the following.
a For check of the exhaust gas color, see "30 Testing and adjusting",
"Testing exhaust gas color".
a When checking the exhaust gas color, perform the "Regeneration
Disable" from the machine monitor.
1. Rapidly accelerate engine from low idle to high idle two times, and
then keep engine running at high idle for 5 seconds.
5 Unusual exhaust gas color • If excessive black smoke is exhausted when accelerating engine or
running it at high idle, troubleshoot for "S-9 KDPF gets clogged in a
short time".
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
a Check that no failure code appears.
a When you finish the check of the exhaust gas color, release
"Regeneration Disable".
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k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • If failure code [CA1923] is also displayed, the ground (GND) leads may be open.
• This failure code appears if sensor connector is disconnected.
• See failure code [CA1963].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
Defective dosing fuel 2. Disconnect connector SOV2, and connect T-adapter to male side of
2 solenoid valve 2 (drain valve) connector.
Resis- Between SOV2 (male) (2) and (1)
4 to 6 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring Between J2 (female) (8) and (18)
3
harness Resis-
a The resistance is the same as that of 4 to 6 z
tance
dosing fuel solenoid valve 2.
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SOV2, and connect T-adapter to each
Open circuit in wiring harness female side of connectors.
4 (wire breakage or defective a To check open circuit in GND line
contact of connector)
Between J2 (female) (8) and SOV2 (female)
Max. 1 z
Resis- (1)
tance Between J2 (female) (18) and SOV2 (female)
(2) Max. 1 z
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k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • If sensor connector is disconnected, failure code [CA2732] is displayed.
• See failure code [CA1963].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector SOV2, and connect T-adapter to male side of
Defective dosing fuel connector.
2 solenoid valve 2 (drain valve) Between SOV2 (male) (2) and (1) 4 to 6 z
Resis-
Between SOV2 (male) (1) and ground (dosing
tance Min. 1 Mz
fuel valve 2 body)
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring Between J2 (female) (8) and (18)
3
harness Resis-
a The resistance is the same as that of 4 to 6 z
tance
dosing fuel solenoid valve 2.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors J2 and SOV2, and connect T-adapter to
4 harness female side of either connector.
(contact with ground circuit) Resis- Between ground (frame) and J2 (female) (8) or
SOV2 (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SOV2, and connect T-adapter to
female side of connector J2.
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k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • Method of reproducing failure code: Turn starting switch to ON position
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approx. 3 minutes, repair is completed.
No. Cause Procedure, measuring location, criteria and remarks
Reverse connection of wiring
1 1. Check connectors SOV1 and SOV2.
harness
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1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor
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1 Injector trim data mismatch a When replacing injectors, see chapter 30 Testing and adjusting,
"Injector trim".
WA470-7 40-377
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47600 (V))
Related • Pressure detected by dosing fuel pressure sensor can be checked with monitoring
information function. (Code: 47601 (kPa))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• Method of reproducing failure code: Start the engine (observe for 3 minutes).
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approx. 3 minutes, repair is completed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
2 Defective fuel system For above check, see Testing and adjusting, "Measuring fuel pressure".
Defective dosing fuel
If failure code [CA1923], [CA1924] or [CA1925] is also displayed,
3 solenoid valve 1 (shut-off
perform troubleshooting for [CA1923], [CA1924] or [CA1925] first.
valve)
Defective dosing fuel If failure code [CA2732] or [CA2733] is also displayed, perform
4 solenoid valve 2 (drain valve) troubleshooting for [CA2732] or [CA2733] first.
Defective dosing fuel If failure code [CA1927] or [CA1928] is also displayed, perform
5 pressure sensor troubleshooting for [CA1927] or [CA1928] first.
1. Turn starting switch to OFF position.
2. Disconnect connector SOV2, and connect T-adapter to female side
Hot short circuit in wiring of connector.
6
harness 3. Turn starting switch to ON position.
Voltage Between SOV2 (female) (1) and (2) Max. 4.7 V
40-378 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-379
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-380 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47600 (V))
General • Pressure sensed by dosing fuel pressure sensor can be checked with monitoring function.
information (Code: 47601 (kPa))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
completing repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective dosing fuel
If failure code [CA1923] or [CA1924] or [CA1925] is also displayed, perform
2 solenoid valve 1 (shut-
troubleshooting for [CA1923] or [CA1924] or [CA1925] first.
off valve)
Defective dosing fuel
If failure code [CA2732] is also displayed, perform troubleshooting for
3 solenoid valve 2 (drain
[CA2732] first.
valve)
Defective dosing fuel If failure code [CA1927] or [CA1928] is also displayed, perform
4 pressure sensor troubleshooting for [CA1927] or [CA1928] first.
Defective fuel supply If failure code [CA559] is also displayed, perform troubleshooting for [CA559]
5 pump first.
WA470-7 40-381
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-382 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
a Failure codes [CA3313], [CA3316], and [CA3321] may remain in the abnormality record on rare
occasions.
6. Turn starting switch to OFF position.
7. Connect the disconnected sensor connectors.
8. If automatic regeneration is started and fuel pressure of fuel doser increases properly by performing the
preceding operations 1 and 2, the failure code is cleared.
*: When automatic regeneration is not started
In the following cases, automatic regeneration may not be started after performing the preceding operations
1 and 2. At that time, perform the operations 3 to 8.
• When "Regeneration Disable" is set from machine monitor.
• When failure code [CA2881] appears during regeneration for service.
• When failure code [CA2881] appears during automatic regeneration or manual stationary regeneration of
user mode, and also machine is operated for long period at heavy load (under high exhaust temperature)
after the regeneration.
WA470-7 40-383
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-384 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-385
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [CA3133] KDPF Outlet Press Sens High Error (WA500_7-CA3133-400-A-Z0-
A)
Action level Failure code KDPF Outlet Pressure Sensor High Error
Failure
L03 CA3133 (Engine controller system)
Detail of • High voltage appears in signal circuit of KDPF outlet pressure sensor.
failure
• Takes it that KDPF delta pressure is at estimated value (gauge pressure) and allows
Action of engine to run.
controller (Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
Problem on • None in particular
machine
k Since KDPF is heated to 500°C or above, take care not to get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1695] is not displayed but failure code [CA1879] is on screen, GND
Related circuit probably has open circuit (defective contact of connector).
information • Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47001 (V))
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47000 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.
Defective KDPF outlet If this failure code changes to [CA3134], KDPF outlet pressure sensor is
3 pressure sensor defective.
a If this failure code remains displayed, wiring harness or engine
controller is defective.
a Ignore other displayed failure codes.
a If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and E25, and connect T-adapters to
4 each female side.
(wire breakage or defective
contact of connector) a To check open circuit in GND line
Resis- Between EC3 (female) (43) and E25 (female)
(1) Max. 1 z
tance
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40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-387
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [CA3134] KDPF Outlet Press Sens Low Error (WA500_7-CA3134-400-A-Z0-
A)
Action level Failure code KDPF Outlet Pressure Sensor Low Error
Failure
L03 CA3134 (Engine controller system)
Detail of • Low voltage appears in signal circuit of KDPF outlet pressure sensor.
failure
• Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
Action of engine to run
controller (Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
Problem on • None in particular
machine
k Since KDPF is heated to 500°C or above, take care not to get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1696] is not displayed but failure code [CA1881] is on screen, sensor
connector is probably disconnected or 5 V circuit probably has open circuit (defective
Related contact of connector).
information • This failure code appears if sensor connector is disconnected.
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47001 (V))
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47000 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
each female side.
a If no failure is found by check on cause 2,
Open circuit in wiring this check is not required. Max. 1 z
harness Between EC3 (female) (43) and E25
3 (female) (1)
(wire breakage or defective
contact of connector) Resis-
a If no failure is found by check on cause 2,
tance
this check is not required. Max. 1 z
Between EC3 (female) (52) and E25
(female) (4)
Between EC3 (female) (58) and E25
(female) (3) Max. 1 z
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40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-389
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [CA3135] KDPF Outlet Press Sens In Range Error (WA500_7-CA3135-
400-A-Z0-A)
Action level Failure code KDPF Outlet Pressure Sensor In Range Error
Failure
L03 CA3135 (Engine controller system)
Detail of • Pressure value sensed by KDPF outlet pressure sensor is higher than normal value.
failure (Signal voltage is within operating range.)
• Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
Action of engine to run
controller (Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
Problem on • None in particular
machine
k Since KDPF is heated to 500°C or above, take care not to get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47001 (V))
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47000 (kPa))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
Related function. (Code: 47400 (°C))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
a Use "Short-circuit connector: 799T-601-4670" (its wiring is not identical with that of "Short-
circuit connector: 799T-601-4611).
• As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute minimum before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and repair
Machine O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after repair trouble.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power supply 1. Turn starting switch to OFF position.
1 system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. See descriptions of wiring harness and connectors in "c: Electrical
2 Defective harness connector equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it and fix trouble as
needed.
40-390 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-391
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Place machine on a level ground and set parking brake lever to LOCK position.
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40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since exhaust connector and KDPF are heated to 500 °C or above, take care not to
get burn injury.
• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47600 (V))
• Pressure sensed by dosing fuel pressure sensor can be checked with monitoring function.
Related (Code: 47601 (kPa))
information • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• For the cleaning method of the fuel doser, see Chapter 30 Testing and adjusting
"Procedures for cleaning fuel doser".
• Since this failure code has no action level, it is not displayed in the user screen of the
machine monitor. It is displayed in the service screen of the machine monitor and
KOMTRAX.
When this failure code appears, perform troubleshooting according to following work flow.
A: Identification of cause
O
B: Fuel doser memory reset
a When this failure code is displayed, the fuel doser injection amount is corrected. After
repair trouble, it is necessary to reset the corrected information of fuel doser injection
amount. Be sure to perform the fuel doser memory reset after repair.
a If it is not performed, there is a danger that KCSF may be damaged.
You can cancel above measure by "turning starting switch to the OFF position" once, then
Machine "turning starting switch to the ON position" after failure code is generated.
operation for
clearing a In the following cases, this failure code does not disappear by simply "turning starting
failure code switch to ON position from OFF position". It disappears after performing the next
automatic regeneration.
1. After this failure code is displayed, any other failure code related to fuel doser is displayed
before "turning starting switch to the OFF position" is performed.
2. After this failure code is displayed, "B. Fuel doser memory reset" is performed before
"turning starting switch to the OFF position" is performed.
3. After this failure code is displayed, the automatic regeneration is performed before
"turning starting switch to the OFF position" is performed.
a When service tool "INSITE" is available, you can clear every failure code by executing
"Reset All Faults" command.
For how to use "INSITE", see "INSITE" operation manual.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it and fix trouble as
needed.
Defective dosing fuel If failure code [CA1927] or [CA1928] is also displayed, perform
2 pressure sensor troubleshooting for [CA1927] or [CA1928] first.
Defective dosing fuel
If failure code [CA1923], [CA1924] or [CA1925] is also displayed,
3 solenoid valve 1 (shut-off
perform troubleshooting for [CA1923], [CA1924] or [CA1925] first.
valve)
WA470-7 40-393
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-394 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-395
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
completing repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is also displayed, perform
1 temperature sensor troubleshooting for [CA3313], [CA3314] or [CA3315] first.
Defective fuel doser If failure code [CA1925] or [CA1963] is also displayed, perform
2 troubleshooting for [CA1925] or [CA1963] first.
solenoid valve 1
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
3
harness connector troubleshooting", and check it and repair as needed.
40-396 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-397
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-398 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
General function. (Code: 47201 (V))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Since cylinders other than disabled cylinder increase their fuel injection to compensate
for torque drop, exhaust temperature may rise and KDOC inlet temperature high error
may be generated.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute or more before turning starting switch
to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
WA470-7 40-399
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-400 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-401
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
completing repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
1 temperature sensor troubleshooting for [CA3316], [CA3317] or [CA3318] first.
Defective fuel doser If failure code [CA1925] or [CA1963] is also displayed, perform
2 troubleshooting for [CA1925] or [CA1963] first.
solenoid valve 1
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
3
harness connector troubleshooting", and check it and repair as needed.
40-402 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-403
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-404 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
General function. (Code: 47400 (°C))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute or more before turning starting switch
to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
WA470-7 40-405
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-406 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-407
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-408 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately100 to 250°C, and
difference between these temperatures is approximately 10°C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
completing repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is also displayed, perform
1 temperature sensor troubleshooting for [CA3319], [CA3321] or [CA3322] first.
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
2
harness connector troubleshooting", and check it and repair as needed.
WA470-7 40-409
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-410 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-411
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
General • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
information function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing C. Machine operation for confirming completion of repair
failure code
a This failure code is cleared when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
1 temperature sensor troubleshooting for [CA3316], [CA3317] or [CA3318] first.
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring
2 equipment" in "Checks before troubleshooting" of "General information on
harness connector
troubleshooting", and check it and repair as needed.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and TEMP2 (KDOC outlet temperature
sensor), and connect T-adapter to female side of EC3.
Short circuit in wiring
3 a Check by using multimeter in continuity mode.
harness
No continuity
Between EC3 (female) (48) and each
Continuity (No sound is heard)
pin other than pin (48)
40-412 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-413
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-414 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing C. Machine operation for confirming completion of repair
failure code
a This failure code is cleared when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is also displayed, perform
1 temperature sensor troubleshooting for [CA3319], [CA3321] or [CA3322] first.
Defective fuel doser If failure code [CA1925] or [CA1963] is also displayed, perform
2 troubleshooting for [CA1925] or [CA1963] first.
solenoid valve 1
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "General information on
3
harness connector troubleshooting", and check it and repair as needed.
WA470-7 40-415
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-416 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-417
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error (WA470_7-CA3313-400-A-Z0-
A)
Action level Failure code KDOC Inlet Temperature Sensor Low Error
Failure
L03 CA3313 (Engine controller system)
Detail of • Low voltage appears in KDOC inlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDOC
Action of inlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3314] for "High Error" appears.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
40-418 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-419
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-420 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [CA3314] KDOC Inlet Temp Sens High Error (WA470_7-CA3314-400-A-Z0-A)
Action level Failure code KDOC Inlet Temperature Sensor High Error
Failure
L03 CA3314 (Engine controller system)
Detail of • High voltage appears in KDOC inlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDOC
Action of inlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
General function. (Code: 47200 (°C))
information • This failure code appears if sensor connector is disconnected.
• If failure codes [CA3317] and [CA3319] are also displayed, connector in KDPF
temperature sensor consolidating box may be disconnected or probably has open circuit
(defective contact of connector) in ground line.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
WA470-7 40-421
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-422 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3 or 4, this check is not required.
harness 1. Turn starting switch to OFF position.
7 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (45) and E26 (female) (3) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
8
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (45) and each No continuity
Continuity
pin other than pin (45) (No sound is heard)
1. Turn starting switch to ON position.
2. If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
9
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
WA470-7 40-423
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-424 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error (WA470_7-CA3315-400-
A-Z0-A)
Action level Failure code KDOC Inlet Temperature Sensor In Range Error
Failure
L03 CA3315 (Engine controller system)
• Difference between temperature sensed by KDOC inlet temperature sensor and that by
Detail of KDOC outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDOC
Action of inlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
General • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait one minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC inlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for
1 temperature sensor it first.
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
2
harness connector troubleshooting", and check it and repair as needed.
WA470-7 40-425
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-426 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 4, this check is not required.
harness 1. Turn starting switch to OFF position.
8 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (45) and E26 (female) (3) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
9 2. Disconnect connectors EC3 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and EC3 (female) (45) or E26
Resistance (female) (3) Min. 1 Mz
WA470-7 40-427
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-428 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-429
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [CA3316] KDOC Outlet Temp Sens Low Error (WA470_7-CA3316-400-A-Z0-
A)
Action level Failure code KDOC Outlet Temperature Sensor Low Error
Failure
L03 CA3316 (Engine controller system)
Detail of • Low voltage appears in KDOC outlet temperature sensor circuit.
failure
• Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor as well, controller sets KDOC
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3317] for "High Error" appears.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
40-430 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-431
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-432 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [CA3317] KDOC Outlet Temp Sens High Error (WA470_7-CA3317-400-A-Z0-
A)
Action level Failure code KDOC Outlet Temperature Sensor High Error
Failure
L03 CA3317 (Engine controller system)
Detail of • High voltage appears in KDOC outlet temperature sensor circuit.
failure
• Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor as well, controller sets KDOC
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
General function. (Code: 47200 (°C))
information • This failure code appears if sensor connector is disconnected.
• If failure codes [CA3314] and [CA3319] are also displayed, connector in KDPF
temperature sensor consolidating box may be disconnected or probably has open circuit
(defective contact of connector) in ground line.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
WA470-7 40-433
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-434 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3 or 4, this check is not required.
harness 1. Turn starting switch to OFF position.
7 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (48) and E26 (female) (1) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
8
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (48) and each No continuity
Continuity
pin other than pin (48) (No sound is heard)
1. Turn starting switch to ON position.
If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
9
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
WA470-7 40-435
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-436 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error (WA470_7-CA3318-
400-A-Z0-A)
Action level Failure code KDOC Outlet Temperature Sensor In Range Error
Failure
L03 CA3318 (Engine controller system)
• Difference between temperature sensed by KDOC outlet temperature sensor and that by
Detail of KDOC inlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
• Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor as well, controller sets KDOC
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
General • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC outlet If failure code [CA3316] or [CA3317] is displayed, perform troubleshooting for
1 temperature sensor it first.
Defective wiring 1. See descriptions of wiring harness and connectors in "c: Electrical
2 equipment" in "Checks before troubleshooting" of "General information on
harness connector
troubleshooting", and check it and repair as needed.
WA470-7 40-437
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-438 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 4, this check is not required.
harness 1. Turn starting switch to OFF position.
8 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (48) and E26 (female) (1) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
9 2. Disconnect connectors EC3 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and EC3 (female) (48) or E26
Resistance (female) (1) Min. 1 Mz
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Troubleshooting by failure code (Display of code)
Failure code [CA3319] KDPF Outlet Temp Sens High Error (WA470_7-CA3319-400-A-Z0-
A)
Action level Failure code KDPF Outlet Temperature Sensor High Error
Failure
L03 CA3319 (Engine controller system)
Detail of • High voltage appears in KDPF outlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDPF
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
General function. (Code: 47200 (°C))
information • This failure code appears if sensor connector is disconnected.
• If failure codes [CA3314] and [CA3317] are also displayed, connector in KDPF
temperature sensor consolidating box may be disconnected or probably has open circuit
(defective contact of connector) in ground line.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
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Open circuit in wiring a If no failure is found by check on cause 3 or 4, this check is not required.
harness 1. Turn starting switch to OFF position.
7 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (54) and E26 (female) (4) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
8
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (54) and each No continuity
Continuity
pin other than pin (54) (No sound is heard)
1. Turn starting switch to ON position.
If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
9
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
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WA470-7 40-445
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Failure code [CA3321] KDPF Outlet Temp Sens Low Error (WA470_7-CA3321-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature Sensor Low Error
Failure
L03 CA3321 (Engine controller system)
Detail of • Low voltage appears in KDPF outlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDPF
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3319] for "High Error" appears.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
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Failure code [CA3322] KDPF Outlet Temp Sens In Range Error (WA470_7-CA3322-
400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature Sensor In Range Error
Failure
L03 CA3322 (Engine controller system)
Detail of • Temperature sensed by KDPF outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
• Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDPF
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
General • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait one minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDPF outlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for it
1 temperature sensor first.
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
2
harness connector troubleshooting", and check it.
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Open circuit in wiring a If no failure is found by check on cause 4, this check is not required.
harness 1. Turn starting switch to OFF position.
8 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (54) and E26 (female) (4) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
9 2. Disconnect connectors EC3 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and EC3 (female) (54) or E26
Resistance (female) (4) Min. 1 Mz
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Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error (WA500_7-
CA3419-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage High Error
Failure
L03 CA3419 (Engine controller system)
Detail of • High voltage appears in mass air flow sensor power supply (12 V) circuit.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes [CA356] and [CA357].
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector E27.
3. Turn starting switch to ON position.
Defective mass air flow
2 sensor (internal defect) If this failure code does not appear, mass air flow sensor is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J1.
3. Turn starting switch to ON position.
3 Defective wiring harness If this failure code does not appear, wiring harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to male side.
3. Turn starting switch to ON position.
4 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
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Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error (WA500_7-
CA3421-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage Low Error
Failure
L03 CA3421 (Engine controller system)
Detail of • Low voltage appears in mass air flow sensor power supply (12 V) circuit.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes [CA356] and [CA357].
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector E27.
3. Turn starting switch to ON position.
Defective mass air flow
2 sensor (internal defect) If this failure code does not appear, mass air flow sensor is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J1.
3. Turn starting switch to ON position.
Defective wiring harness or
3 If this failure code does not appear, wiring harness is defective.
connector
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J1 and E27, and connect T-adapters to
4 either female side.
(contact with ground circuit)
Resis- Between ground and J1 (female) (21) or E27
(female) (2) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to
5 Short circuit in wiring harness either female side.
Resis- Between J1 (female) (21) and (22), or between
E27 (female) (2) and (3) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to male side.
3. Turn starting switch to ON position.
6 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
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40-460 WA470-7
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WA470-7 40-461
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WA470-7 40-463
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40-464 WA470-7
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WA470-7 40-465
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WA470-7 40-467
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Failure code [D160KY] Hot Short of Backup Lamp Relay Output (WA470_7-
D160KY-400-A-Z0-A)
Action level Failure code Hot Short of Backup Lamp Relay Output
Failure
L01 D160KY (Transmission controller system)
Detail of • When controller does not drive primary circuit (coil side) of backup lamp relay, current
failure flows through circuit.
• Stops driving primary circuit (coil side) of backup lamp relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Backup lamp continues to light up.
machine • Backup alarm buzzer continues to sound.
• Output signal (ON/OFF) to backup lamp relay can be checked with monitoring function.
(Code: 03705 Backup Lamp Relay)
Related • This failure code indicates failure on primary circuit (coil side) of backup lamp relay, but
information not on secondary circuit (contact side).
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
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WA470-7 40-469
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Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors D11 and L116, and connect T-adapters to each
defective contact of female side.
connector) Between L116 (female) (1) and D12 (female) (1) Max. 1 z
Resistance
Between L116 (female) (2) and ground Max. 1 z
If no failure is found by above checks, transmission controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
5 4. Move directional lever to perform troubleshooting.
controller
Directional lever: N
(neutral) 20 to 30 V
Between L63 (female)
Voltage
(8) and ground Directional lever: Other
than N (neutral) Max. 4.5 V
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Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed).
controller
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WA470-7 40-487
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WA470-7 40-489
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40-490 WA470-7
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WA470-7 40-491
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40-492 WA470-7
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WA470-7 40-493
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Figure of structure
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WA470-7 40-501
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WA470-7 40-503
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WA470-7 40-505
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WA470-7 40-507
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WA470-7 40-509
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Failure code [DAFDKB] Monitor 12V Power Output Short Circuit (WA380_7-
DAFDKB-400-A-Z0-A)
Action level Failure code Monitor 12V Power Output Short Circuit
Failure
L01 DAFDKB (Machine monitor system)
Detail of • When starting switch is turned to ON position, 12 V power supply voltage is 8 V or below,
failure or 14 V or above.
• Stops supplying 12 V power (stops until starting switch is turned to OFF position).
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Switch panel cannot be operated.
Problem on • LED unit does not light up or lights up incorrectly.
machine • If engine start lock is enabled, engine cannot be started because password cannot be
entered.
• If failure code [DAF3KK] (Controller Power Source Low (MON)) is generated, perform
Related troubleshooting for it first.
information • Method of reproducing failure code: Turn starting switch to OFF position, and then to ON
position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors MCM1 B, MDM2, and MOM1, and connect
1 T-adapters to either female side.
(contact with ground circuit)
Resis- Between ground and MCM1 B (female) (107),
MDM2 (female) (1), or MOM1 (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector MCM1 B, and connect T-adapters to female
2 harness side.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between MCM1 B (female) (107) and (99) Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector MCM1 B, and connect T-adapters to male
side.
3 Defective monitor controller
3. Turn starting switch to ON position.
Voltage Between MCM1 B (male) (107) and (99) 9.3 to 14.1
V
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40-518 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-519
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-520 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-521
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-522 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-523
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-524 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-525
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-526 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-527
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-528 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Ground Fault of Solenoid Self-Holding Relay (TM)
Failure
L03 DAQ4KB (Transmission controller system)
• Excessive current flows when the output to primary circuit (coil) of fan pump (solenoid
Detail of self-holding) relay is turned ON. When controller drives primary circuit (coil) of fan pump
failure (solenoid self-holding) relay, large current flows.
• Stops driving fan pump (solenoid self-holding) relay circuit.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • The radiator fan cannot be rotated reversely.
machine (If rotating reversely, it is changed to the normal rotation.)
• Output signal of fan pump (solenoid self-holding) relay can be checked with monitoring
function (Code: 03900).
Related • This failure code detects failure in primary (coil) circuit of fan pump (solenoid self-holding)
information relay. It does not detect failure in secondary (contact) circuit.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fan pump 1. Turn starting switch to OFF position.
1 (solenoid self-holding) 2. Disconnect connector L112 and connect T-adapter to male side.
relay (L112) Resistance Between connector L112 (male) (1) and (2) 290 ± 30 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and L112, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (4) or L112
circuit) Resistance (female) (1) Min. 1 Mz
WA470-7 40-529
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-530 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-531
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-532 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-533
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-534 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-535
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-536 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-537
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-538 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-539
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-540 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-541
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-542 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-543
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-544 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-545
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-546 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-547
40 Troubleshooting
Troubleshooting by failure code (Display of code)
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors MCM1 B, L72, L62, ECM J1, ECM J2, and C23,
and connect T-adapters to each female side.
Between ground and any of L72 (female) (33), L62
Ground fault in wiring (female) (33), MCM1 B (female) (113), MCM1 B Min. 1 Mz
harness (female) (112), and ECM J1 (female) (8)
5
(contact with ground Between ground and ECM J2 (female) (24) or C23
circuit) (female) (A) Min. 1 Mz
Resistance
Between ground and any of L72 (female) (23), L62
(female) (23), MCM1 B (female) (105), and ECM J1 Min. 1 Mz
(female) (18)
Between ground and either of ECM J2 (female) Min. 1 Mz
(25) and B_RES (female) (B)
40-548 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-549
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-550 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DB90KK] Drop in BBC Controller Main Power Source (WA470_7-
DB90KK-400-A-Z0-A)
Action level Failure code Drop in Bucket Boom Controller Controller Main Power Source
Failure
L03 DB90KK (Work equipment controller system)
• Continuous power supply (power supply directly connected to battery) voltage of work
Detail of equipment controller drops.
failure • Continuous power supply (battery direct power supply) voltage is 18 V or less.
• Cannot detect input signals properly.
• Correct the settings so that any failure code, other than this failure code, is not displayed
when the continuous power supply (power supply directly connected to battery) voltage is
Action of 18 V or less for 0.02 second.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until work
equipment lever is set to NEUTRAL position.
Problem on • Since an input signal cannot be detected correctly, normal operation cannot be
machine performed.
Related • If fuse-5 in fuse box 2 is blown, failure codes [DAQQKR] and [DAQRKR] are displayed.
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a Check battery voltage and specific gravity of battery electrolyte.
1 Defective battery Voltage Battery voltage Min. 24 V
Specific
Specific gravity of battery electrolyte Min. 1.26
gravity
Defective slow-blow If slow-blow fuse (R02) is blown, circuit may have ground fault, etc. (See
2 fuse (R02) check on cause 5.)
Defective fuse 3 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 5.)
3
box 2
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector L73, and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
a If voltage appears between battery (+) terminal and ground but not
between ground and each of L73 (1) and (11), wiring harness or fuse has
open circuit.
Open circuit in wiring Between battery (-) terminal and ground 20 to 30 V
harness Voltage Between ground and each of L73 (female) (1) and
4 (wire breakage or (11) 20 to 30 V
defective contact of
connector) a If no failure is found by above checks, this check is not required.
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector L73, and connect T-adapter to female side.
Between ground and each of L73 (female) (21),
(31), (32), and (33) Max. 1 z
Resistance
Between battery (+) terminal and each of L73 (1)
and (11) Max. 1 z
WA470-7 40-551
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-552 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-553
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-554 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Disconnection of Key Switch ACC (Bucket Boom Controller)
Failure
L03 DB91KA (Work equipment controller system)
Detail of • While engine is running, key switch ACC signal is not entered in work equipment
failure controller.
Action of • None in particular
controller
• Work equipment does not operate.
Problem on • If ACC signal lines of both transmission controller and engine controller have open circuit,
machine machine comes into the same state as when engine shutdown secondary switch is
operated.
• If fuse No. 1 or No. 15 in fuse box 2 is blown, nothing is displayed on machine monitor.
Related • When the engine is rotating, power is supplied other than the line between terminal ACC
information of starting switch and work equipment controller.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector L73, and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Open circuit in wiring Between L73 (female) (14) and (21) 20 to 30 V
harness Voltage
Between L73 (female) (24) and (31) 20 to 30 V
1 (wire breakage or
defective contact of a If no failure is found by above checks, this check is not required.
connector) 1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connectors L73 and S40, and connect T-adapters to each
female side.
Between L73 (female) (14) and S40 (female) (4) Max. 1 z
Resistance
Between L73 (female) (24) and S40 (female) (4) Max. 1 z
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector L73.
Defective work 4. Turn battery disconnect switch to ON position.
2 equipment controller 5. Turn starting switch to ON position.
Between L73 (14) and (21) 20 to 30 V
Voltage
Between L73 (24) and (31) 20 to 30 V
WA470-7 40-555
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-556 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Solenoid Power Source Low (Bucket Boom Controller)
Failure
L03 DB92KK (Work equipment controller system)
• 24V solenoid power supply voltage (appears at work equipment controller pins 2, 12, and
22) is 18 V or lower, while controller power supply (continuous power supply voltage from
Detail of battery) is normal.
failure • Detection conditions: Continuous power supply voltage (continuous power supply voltage
from battery) is Min. 20 V and solenoid power supply is Max. 18 V.
• Stops driving solenoids (stops driving all solenoids if solenoid power supply voltage drops
below 18 V).
• Does not allow failure codes to be displayed, that can be falsely generated due to drop in
Action of 24 V solenoid power supply voltage.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until work
equipment lever is set to NEUTRAL position.
Problem on • Work equipment does not operate.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective slow-blow
1 fuse FL (R05 and If slow blow fuse is blown, circuit probably has ground fault.
R06A)
Defective fuse-5 in fuse If fuse is blown, circuit probably has ground fault.
2
box 1
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector L73, and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
a If voltage appears between terminal R07 of battery relay and the ground,
but not between ground and each of L73 (2), (12) and (22), the wiring
Open circuit in wiring harness may be broken or the fuse may be blown.
harness Between battery relay terminal R07 and ground 20 to 30 V
3 (wire breakage or Voltage Between ground and each of L73 (female) (2), (12)
and (22) 20 to 30 V
defective contact of
connector)
a If no failure is found by above checks, this check is not required.
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector L73, and connect T-adapter to female side.
Between ground and each of L73 (female) (21),
(31), (32), and (33) Max. 1 z
Resistance
Between battery (+) terminal and each of L73
(female) (2), (12), and (22) Max. 1 z
WA470-7 40-557
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-558 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-559
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Circuit diagram related to 5V sensor power source (2 levers specification or 3 levers specification)
40-560 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-561
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-562 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Inconsistency of Model Selection (Bucket Boom Controller)
Failure
L03 DB99KQ (Work equipment controller system)
Detail of • Model selection signal sent from monitor controller when starting switch is turned ON
failure differs from the model setting stored in work equipment controller.
• Continues to operate taking it that machine model is same as that before generation of
Action of this failure code.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
Problem on • Work equipment may not operate normally.
machine
• Perform initial setting and initial adjustment similar to those required when the work
Related equipment controller is replaced.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
a Model setting of monitor controller is probably incorrect. After
Defective model setting by replacing the monitor controller or work equipment controller, set the
1
monitor controller model correctly. For details, see Testing and Adjusting, "Special
functions of machine monitor".
Installation of wrong work Wrong work equipment controller may be installed. Check part No. and
2 equipment controller install correct work equipment controller.
If no failure is found by above checks, work equipment controller is
Defective work equipment defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)
If no failure is found by above checks, monitor controller is defective.
4 Defective monitor controller (Since this is an internal defect, troubleshooting cannot be performed.)
WA470-7 40-563
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Operating Lamp Open Circuit (Bucket Boom Controller)
Failure
- DB9LKA (Work equipment controller system)
• The work equipment controller has detected an open circuit because the output line
Detail of voltage of system operating lamp is approximately 5 V or less when the work equipment
failure controller does not output the voltage for approximately 3 seconds after the starting switch
has turned ON.
Action of • It does not output for system operating lamp.
controller
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine work equipment controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although work equipment controller is not able to light up system operating lamp, no
Related trouble will result unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse-4 in fuse If fuse is blown, circuit probably has ground fault.
1
box 2
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Disconnect connectors L73 and R61, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between L73 (female) (34) and R61 (female) (2) Max. 1 z
connector) Resistance Between R61 (female) (1) and battery relay
terminal (R01) Max. 1 z
40-564 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-565
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Operating Lamp Short Circuit (Bucket Boom Controller)
Failure
- DB9LKB (Work equipment controller system)
• Work equipment controller determines that output circuit to system operating lamp shorts
Detail of because voltage of output circuit does not become Low level while work equipment
failure controller drives system operating lamp.
Action of • Stops driving system operating lamp.
controller
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine work equipment controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Although work equipment controller is not able to light up system operating lamp, no
information trouble will result unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
No. Cause Procedure, measuring location, criteria and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
Short circuit in wiring 3.Remove fuse-4 in fuse box 2.
1 4.Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
harness
connect T-adapter to female side of R61.
Resistance Between R61 (female) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Remove fuse-4 in fuse box 2.
Hot short circuit in
2 4. Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
wiring harness
connect T-adapter to female side of R61.
5. Turn battery disconnect switch to ON position.
Voltage Between R61 (female) (2) and ground Max 1 V
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-566 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-567
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-568 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-569
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Inconsistency of Option Selection (Bucket Boom Controller)
Failure
L03 DB9RMA (Work equipment controller system)
Detail of • When starting switch is turned to the ON position, the option setting information sent from
failure machine monitor differs from that stored in the work equipment controller.
Action of • Controls with the option settings stored in the controller.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
Problem on • The option installed does not work normally.
machine
• Perform initial setting and initial adjustment similar to those required when the work
Related equipment controller is replaced.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
The option setting of monitor controller is probably incorrect. After
Defective option setting of replacing the monitor controller or work equipment controller, set the
1
monitor controller options correctly. For details, see Testing and Adjusting.
If no failure is found by check on cause 1, the work equipment controller
Defective work equipment may be defective. (Since this is an internal defect, troubleshooting
2
controller cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
3 Defective monitor controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-570 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-571
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-572 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-573
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-574 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Ground Fault of Remote Positioner Set Switch
Failure
L01 DD1ALD (Work equipment controller system)
• Due to ground fault in remote positioner set switch (boom) circuit, remote positioner
Detail of cannot be set for boom RAISE and LOWER.
failure • Continuous operation for 30 seconds is detected on remote positioner set switch (boom).
• Cancels boom RAISE set position if boom is positioned above horizontal.
• Cancels boom LOWER set position if boom is positioned below horizontal.
Action of • Does not perform remote stop for canceled side.
controller • Turns off remote positioner set indicator for canceled side.
• If cause of failure disappears, machine becomes normal by itself.
Problem on • Both boom RAISE and LOWER set positions cannot be set.
machine • Remote positioner does not perform stop for canceled side.
• Input signal (ON/OFF) from remote positioner set switch can be checked with monitoring
Related function. (Code: 02218 BBC Input 2, Boom Positioner Set SW)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH6, and connect T-adapters to male side.
Remote positioner set
Defective remote Max. 1 z
positioner set switch Between S_RH6 (male) switch: Boom set ON
1 Remote positioner set
(boom) (5) and (6)
Resistance switch: Other than boom Min. 1 Mz
set ON
Between ground and each of S_RH6 (male) (5) and
(6) Min. 1 Mz
WA470-7 40-575
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-576 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-577
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-578 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-579
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-580 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-581
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-582 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-583
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-584 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-585
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-586 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code FNR Switch Input Signal Short Circuit
Failure
L03 DDK3KB (Transmission controller system)
Detail of • Due to hot short circuit of R.H. directional selector (FNR) switch input signal system,
failure multiple signals of R.H. directional selector (FNR) switch are inputted.
• Takes an input signal from R.H. directional selector (FNR) switch as neutral.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until R.H.
directional selector (FNR) switch is set in N (neutral) position.
• Machine does not travel with R.H. directional selector (FNR) switch.
Problem on • Machine can travel by operating directional (FNR) lever.
machine • Multiple pilot lamps of shift lever position light up.
• Input signal (ON/OFF) from R.H. directional selector (FNR) switch can be checked with
monitoring function.
(Code: 02211 Option FNR Signal F, Option FNR signal N, or Option FNR signal R)
Related • Only for machines equipped with R.H. directional selector (FNR) switch (if equipped).
information • Method of reproducing failure code:Turn starting switch to ON position, set directional
selector switch actuation switch to ON position, and operate R.H. directional selector
(FNR) switch.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector S_RHB.
R.H. directional selector
(FNR) switch: F (forward) 20 to 30 V
Between S_RHB (2) and
ground R.H. directional selector
(FNR) switch: Other than Max 1 V
F
R.H. directional selector
Defective R.H. (FNR) switch: N (neutral) 20 to 30 V
Between S_RHB (3) and
directional selector R.H. directional selector
1 ground
(FNR) switch (internal (FNR) switch: Other than Max 1 V
short circuit) Voltage
N
R.H. directional selector
(FNR) switch: R 20 to 30 V
Between S_RHB (4) and (reverse)
ground R.H. directional selector
(FNR) switch: Other than Max 1 V
R (reverse)
Between S_RHB (1) and
ground Continuous 20 to 30 V
WA470-7 40-587
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-588 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-589
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-590 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-591
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit (WA380_7-DDK6KB-400-
A-Z0-A)
Action level Failure code FNR Lever Input Signal Short Circuit
Failure
L03 DDK6KB (Transmission controller system)
Detail of • Multiple signals of directional (FNR) lever switch are input due to hot short in directional
failure (FNR) lever switch signal system.
• Follows lever position recognition by analog input.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Multiple pilot lamps of shift lever position light up.
machine
• Input signal (ON/OFF) from directional (FNR) lever switch can be checked with monitoring
Related function (Code: 02211, Main FNR Signal F, Main FNR Signal N, or Main FNR Signal R).
information • Method of reproducing failure code: Turn starting switch ON and operate directional
(FNR) lever
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch OFF.
2. Insert T-adapter into connector L02.
3. Turn starting switch ON.
Between L02 (1) and
(9) Constant 20 to 30 V
Directional (FNR)
Between L02 (3) and lever: N (NEUTRAL) 20 to 30 V
Defective directional (FNR) (9) Directional (FNR)
1 lever switch (internal short Max. 1 V
lever: Other than N
circuit) Directional (FNR)
Voltage 20 to 30 V
Between L02 (2) and lever: F (FORWARD)
(9) Directional (FNR)
Max. 1 V
lever: Other than F
Directional (FNR)
Between L02 (4) and lever: R (REVERSE) 20 to 30 V
(9) Directional (FNR)
Max. 1 V
lever: Other than R
1. Turn starting switch OFF.
2. Disconnect connector L02 and connect T-adapter to female side.
Hot short circuit in wiring 3. Turn starting switch ON.
2 harness (contact with 24 V
Between L02 (female) (4) and ground Max. 1 V
circuit)
Voltage Between L02 (female) (3) and ground Max. 1 V
Between L02 (female) (2) and ground Max. 1 V
40-592 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-593
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Hot Short of Work Equipment Lock Switch
Failure
L03 DDNRKY (Work equipment controller system)
Detail of Due to hot short circuit in work equipment lock switch circuit, work equipment lock remains
failure released or applied.
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
• Condition of work equipment lock switches (work equipment lock is released if it has been
Problem on applied, or it is applied if it has been released).
machine • Once condition of work equipment lock is changed, it is fixed and cannot be changed.
• Output signal (ON/OFF) from work equipment lock switch can be checked with monitoring
Related function. (Code: 02217BBC Input 1, Work Equipment Lock SW)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RHC and replace switch with another one of
same type.
3. Turn starting switch to ON position.
If failure code [DDNRKY] disappears, original work equipment lock switch is
Defective work defective.
1 equipment lock switch 4. Turn starting switch to OFF position.
5. Disconnect connector S_RHC and connect T-adapter to male side.
Work equipment lock
Between S_RHC (male) Min. 1 Mz
switch: OFF
Resistance (5) and (6)
Work equipment lock
Max. 1 z
switch: ON
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector S_RHC and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between S_RHC (female) (6) and ground Max. 1 V
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-594 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-595
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-596 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-597
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal (WA470_7-
DDT4LD-400-A-Z0-A)
Action level Failure code Ground Fault of Transmission Cut Off Set Switch Signal
Failure
L01 DDT4LD (Transmission controller system)
Detail of • Transmission cut-off is not performed normally due to ground fault in transmission cut-off/
failure set switch circuit.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Problem on • Transmission cut-off is performed at unintended timing.
machine
• Input signal (ON/OFF) from transmission cut-off switch can be checked with monitoring
Related function. (Code: 02214 T/M Cut Off Switch)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH1, and connect T-adapters to male side.
Transmission cut-off set
Defective transmission Between S_RH1 (male) Max. 1 z
switch: ON
1 cut-off switch (internal (4) and (5) Transmission cut-off set
short circuit) Min. 1 Mz
Resistance switch: OFF
Between ground and
each of S_RH1 (male) Continuous Min. 1 Mz
(4) and (5)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and S_RH1, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (30) or S_RH1
circuit) Resistance (female) (4) Min. 1 Mz
40-598 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-599
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal (WA470_7-DDT9LD-
400-A-Z0-A)
Action level Failure code Ground Fault of Transmission Cut Off Switch Signal
Failure
L01 DDT9LD (Transmission controller system)
Detail of • Transmission cut-off is not normally performed due to ground fault in transmission cut-off
failure set switch system.
• Recognizes input of transmission cut-off once when ground fault occurs, and then does
Action of not control transmission cut-off any more.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Transmission cut-off is performed at unintended timing.
machine
• Input signal (ON/OFF) from transmission cut-off switch can be checked with monitoring
Related function. (Code: 02214 T/M Cut Off Switch)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH1, and connect T-adapters to male side.
Transmission cut-off
Defective transmission Between S_RH1 (male) Max. 1 z
switch:ON
1 cut-off switch (internal (5) and (6) Transmission cut-off
short circuit) Min. 1 Mz
Resistance switch:OFF
Between ground and
each of S_RH1 (male) Continuous Min. 1 Mz
(5) and (6)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and S_RH1, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (20) or S_RH1
circuit) Resistance (female) (6) Min. 1 Mz
40-600 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-601
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-602 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-603
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Ground Fault of Transmission Shift Hold SWITCH
Failure
L01 DDWLLD (Transmission controller system)
Detail of • Holding operation cannot be performed because of ground fault in hold switch system.
failure
• Performs holding operation once when ground fault occurs, and then does not control
Action of holding operation any more.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Transmission is held once when ground fault occurs.
machine
• Input condition (ON/OFF) from the kickdown switch can be checked with monitoring
Related function
information (Code: 02212 Hold Switch)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L14 and connect T-adapter to male side.
Defective hold switch Between L14 (male) (3) Hold switch:ON Max. 1 z
1 and (4) Hold switch:OFF Min. 1 Mz
(internal short circuit)
Resistance Between ground and
each of L14 (male) (3) Continuous Min. 1 Mz
and (4)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and L14, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (19) or L14
circuit) Resistance (female) (3) Min. 1 Mz
40-604 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-605
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-606 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-607
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-608 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-609
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-610 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-611
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connector L61, and connect T-adapters to female side.
defective contact of 3. Disconnect connector TM.T and connect T-adapter to female side.
connector) Between L61 (female) (4) and TM.T (female) (2) Max. 1 z
Resistance
Between L61 (female) (9) and TM.T (female) (1) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed).
controller
For average resistance of sensors at each temperature, see [DGR2KB].
40-612 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor (WA380_7-DGF1KB-
400-A-Z0-A)
Action level Failure code Ground Fault of Transmission Oil Temperature Sensor
Failure
L01 DGF1KB (Transmission controller system)
• Due to ground fault of transmission oil temperature sensor signal system, transmission oil
Detail of temperature signal is lower than the normal range.
failure (Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Cannot determine transmission oil temperature correctly.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Gear shift shock may occur.
machine
• Input voltage from transmission oil temperature sensor can be checked with monitoring
function.
(Code: 32501 T/M Oil Temp. Sensor Volt)
Related • Oil temperature sensed by transmission oil temperature sensor can be checked with
information monitoring function.
(Code: 32500 T/C Oil Temperature)
• Method of reproducing failure code: Turn starting switch ON.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch OFF.
2. Disconnect connector TM.T and connect T-adapter to male side.
Defective transmission oil Between Oil temperature: 25°C
1 temperature sensor 35 to 50 kz *
Resis- TM.T (Normal temperature)
tance (male) (1)
and (2) Oil temperature: 100°C 3.1 to 4.5 kz *
1. Turn starting switch OFF.
2. Disconnect connector L61 and connect T-adapter to female side.
Open or short circuit in wiring Between Oil temperature: 25°C
2 37 to 50 kz
harness Resis- L61 (Normal temperature)
tance (female)
(9) and (4) Oil temperature: 100°C 3.1 to 4.5 kz
1. Turn starting switch OFF.
2. Disconnect connectors L61 and TM.T, and connect T-adapters to
3 Ground fault in wiring harness each female side.
Resis- Between ground and L61 (female) (9) or TM.T
(female) (1) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed).
*: For average resistance of sensors at each temperature, see [DGR2KB].
WA470-7 40-613
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-614 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor (WA470_7-DGH2KX-
400-A-Z0-A)
Action level Failure code Out of Range of Hydraulic Oil Temperature Sensor
Failure
L01 DGH2KX (Transmission controller system)
• Due to ground fault in signal circuit of hydraulic oil temperature sensor, hydraulic oil
Detail of temperature signal is lower than normal range.
failure (Signal voltage from hydraulic oil temperature sensor: 0.97 V or below (150°C or above))
Action of • Cannot determine hydraulic oil temperature correctly.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Pointer of hydraulic oil temperature gauge is not displayed.
machine
• Input voltage from hydraulic oil temperature sensor can be checked with monitoring
function.
(Code: 04404 Hydr. Oil Temp. Sensor Volt)
Related • Oil temperature sensed by hydraulic oil temperature sensor can be checked with
information monitoring function.
(Code: 04401 Hydr. Oil Temperature)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R47 and connect T-adapter to male side.
Defective hydraulic oil Hydraulic oil
1 temperature: 25°C 35 to 50 kz
temperature sensor Between R47 (male) (1) (normal temperature) *
Resistance and (2)
Hydraulic oil 3.1 to 4.5
temperature: 100°C kz *
1. Turn starting switch to OFF position.
2. Disconnect connector R47 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Open circuit, short
circuit, ground fault, hot a Voltage of approx. 5 V is applied to temperature sensor signal circuits
2 short circuit of wiring through resistor in transmission controller.
harness, or defective
a Shake the wiring harness by hand while measuring the voltage. If the
transmission controller
voltage drops to approximately 0 V during shaking, circuit is open around
this point.
Voltage Between R47 (female) (1) and (2) Approx. 5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector L61 and connect T-adapter to female side.
Open or short circuit in Hydraulic oil
3 wiring harness temperature: 25°C 35 to 50 kz
Between L61 (female) (normal temperature)
Resistance (20) and (4)
Hydraulic oil 3.1 to 4.5
temperature: 100°C kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors L61 and R47, and connect T-adapter to either
4
harness female side.
Between ground and L61 (female) (20) or R47
Resistance (female) (1) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed).
controller
* For average resistance of sensors at each temperature, see [DGR2KB].
WA470-7 40-615
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-616 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor (WA380_7-
DGR2KB-400-A-Z0-A)
Action level Failure code Ground Fault of Brake Oil Temperature Sensor
Failure
L01 DGR2KB (Monitor controller system)
Detail of • Voltage of signal circuit of brake oil temperature sensor (rear) drops below 0.97 V or
failure increases above 175 °C.
Action of • Light up system caution lamp.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Oil temperature gauge is disabled due to failure code in sensor.
machine
• Signal from brake oil temperature sensor can be checked with monitoring function.
Related (Code: 30202 (°C), 30205 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R60 and connect T-adapter to male side.
Rear brake oil
temperature: 25°C 42.7 kz *
Rear brake oil
Defective brake oil temperature: 30°C 35.13 kz *
1 temperature sensor (rear) Resis- Between R60 (male) Rear brake oil
(1) and (2) temperature: 80°C 6.556 kz *
tance
Rear brake oil
temperature: 90°C 4.925 kz *
Rear brake oil
temperature: 100°C 3.75 kz *
WA470-7 40-617
40 Troubleshooting
Troubleshooting by failure code (Display of code)
• Signal from brake oil temperature sensor can be checked with monitoring function.
Related (Code: 30202 (°C), 30205 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
40-618 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-619
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Disconnection of Torque Converter Oil Temperature Sensor
Failure
L01 DGT1KA (Transmission controller system)
• Due to open circuit in torque converter oil temperature sensor signal system, torque
Detail of converter oil temperature signal is higher than normal range (torque converter oil
failure temperature sensor signal voltage: Min. 4.56 V (Max. 15°C)), and transmission oil
temperature sensor signal voltage: Max. 3.7 V (Min. 55°C).
• Cannot determine torque converter oil temperature correctly.
Action of • Controls fan, ignoring torque converter oil temperature.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Fan speed may not be set properly, and that can cause overheat.
machine
• Input voltage from transmission oil temperature sensor can be checked with monitoring
function.
(Code: 32501 T/M Oil Temp. Sensor Volt)
• Oil temperature sensed by transmission oil temperature sensor can be checked with
monitoring function.
(Code: 32500 T/M Oil Temperature)
Related • Input voltage from torque converter oil temperature sensor can be checked with
information monitoring function.
(Code: 30101 T/C Oil Temp. Sensor Volt)
• Oil temperature sensed by torque converter oil temperature sensor can be checked with
monitoring function.
(Code: 30100: T/C Oil Temperature)
• Method of reproducing failure code: Turn starting switch to ON position.
a To access connector TC.T, see the illustration.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector TC.T and connect T-adapter to male side.
Torque converter oil
Defective torque temperature: 35 to 50 kz
1 converter oil 25°C (Normal *
temperature sensor Between TC.T (male) (1)
Resistance and (2) temperature)
Torque converter oil
temperature: 3.1 to 4.5
kz *
100°C
1. Turn starting switch to OFF position.
2. Disconnect connector TC.T and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open circuit, short
circuit, ground fault, hot a Voltage of approx. 5 V is applied to temperature sensor signal circuits
short circuit of wiring through resistor in transmission controller.
2
harness, or defective a Shake the wiring harness by hand while measuring the voltage. If the
transmission controller voltage drops to approximately 0 V during shaking, circuit is open around
this point.
Voltage Between TC.T (female) (1) and (2) Approx. 5 V
40-620 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connector L61, and connect T-adapters to female side.
defective contact of 3. Disconnect connector TC.T and connect T-adapter to female side.
connector) Between L61 (female) (4) and TC.T (female) (2) Max. 1 z
Resistance
Between L61 (female) (3) and TC.T (female) (1) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed).
controller
For average resistance of sensors at each temperature, see [DGR2KB].
WA470-7 40-621
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-622 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor (WA470_7-DGT1KB-
400-A-Z0-A)
Action level Failure code Ground Fault of Torque Converter Oil Temperature Sensor
Failure
L01 DGT1KB (Transmission controller system)
• Due to ground fault of torque converter oil temperature sensor signal system, torque
Detail of converter oil temperature signal is lower than the normal range.
failure (Torque converter oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
• Cannot determine torque converter oil temperature correctly.
Action of • Controls fan, ignoring torque converter oil temperature.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Fan speed may not be set properly, and that can cause over-cooling.
machine
• Input voltage from torque converter oil temperature sensor can be checked with
monitoring function.
(Code: 30101 T/C Oil Temp. Sensor Volt)
Related • Oil temperature sensed by torque converter oil temperature sensor can be checked with
information monitoring function.
(Code: 30100: T/C Oil Temperature)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector TC.T and connect T-adapter to male side.
Torque converter oil
Defective torque temperature: 35 to 50 kz
1 converter oil 25°C (Normal *
temperature sensor Between TC.T (male) (1)
Resistance and (2) temperature)
Torque converter oil
temperature: 3.1 to 4.5
kz *
100°C
1. Turn starting switch to OFF position.
2. Disconnect connector L61, and connect T-adapters to female side.
Torque converter oil
temperature:
Open or short circuit in 35 to 50 kz
2 wiring harness 25°C (Normal
Between L61 (female)
Resistance (3) and (4) temperature)
Torque converter oil
temperature: 3.1 to 4.5
kz
100°C
1. Turn starting switch to OFF position.
2. Disconnect connector L61 and TC.T, connect T-adapter to either female
Ground fault in wiring
3 side.
harness
Between ground and L61 (female) (3) or TC.T
Resistance (female) (1) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed).
controller
For average resistance of sensors at each temperature, see [DGR2KB].
WA470-7 40-623
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-624 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-625
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-626 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit (WA470_7-
DH21KB-400-A-Z0-A)
Action level Failure code Loader Pump Pressure Sensor Short Circuit
Failure
L01 DH21KB (Work equipment controller system)
• Due to hot short in loader pump pressure sensor system, loader pump pressure sensor
Detail of signal voltage is higher than the normal range.
failure (Loader pump pressure sensor signal voltage: Min. 4.42 V)
Action of • Operates, assuming loader pump pressure to be 0 MPa.
controller • If cause of failure disappears, machine becomes normal by itself.
• Cut-off operation is not performed when oil is relieved.
• Accuracy of remote positioner decreases.
Problem on • Engine does not pick up normally.
machine • Komatsu SmartLoader Logic malfunctions.
• Eco guidance function does not work normally.
• Input voltage from loader pump pressure sensor can be checked with monitoring function.
(Code: 94701 Loader Pump Pres. Sensor Volt)
Related • Oil pressure sensed by loader pump pressure sensor can be checked with monitoring
information function.
(Code: 94700 Loader Pump Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
1 system of loader pump 2. Disconnect connector F10 and connect T-adapter to female side.
pressure sensor 3. Turn starting switch to ON position.
Power 5.00 to 5.20
Voltage Between F10 (female) (B) and (A)
supply input V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F10.
3. Start engine.
Defective loader pump Loader pump pressure: 0.50 to 4.40
pressure sensor Continuous V
2
(internal open or short Voltage Between F10 (C) and (A) Loader pump pressure: 0.50 to 0.90
circuit) At Neutral V
Loader pump pressure: 2.80 to 3.20
At bucket tilt relief V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector F10 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(contact with 24V
circuit) Voltage Between F10 (female) (C) and ground Max 1 V
If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
Defective work 3. Start engine and tilt bucket
4 equipment controller Loader pump pressure: 0.50 to 4.40
Continuous V
Between L71 (9) and Loader pump pressure: 0.50 to 0.90
Voltage
ground at Neutral V
Loader pump pressure: 2.80 to 3.20
Bucket tilt V
WA470-7 40-627
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-628 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-629
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-630 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-631
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-632 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor (WA470_7-
DHPDKX-400-A-Z0-A)
Action level Failure code Out of Range of Boom Head Pressure Sensor
Failure
L01 DHPDKX (Work equipment controller system)
• Due to open circuit, ground fault, or hot short circuit in boom cylinder head pressure
Detail of sensor circuit, signal voltage of boom cylinder pressure is out of normal range.
failure (Signal voltage from boom cylinder head pressure sensor: Less than 0.3 V, or 4.42 V or
above)
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Problem on • Load is not displayed.
machine
• Input voltage from boom cylinder head pressure sensor can be checked with monitoring
function.
(Code: 40501 Boom Head Pres. Sensor Volt)
Related • Oil pressure sensed by boom cylinder head pressure sensor can be checked with
information monitoring function.
(Code: 40500 Boom Head Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply
system of boom 1. Turn starting switch to OFF position.
1 2. Disconnect connector F13 and connect T-adapter to female side.
cylinder head pressure
sensor 3. Turn starting switch to ON position.
Power
Voltage Between F13 (female) (B) and (A)
supply input 5.0 to 5.2 V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F13.
3. Start engine, and troubleshoot by lowering boom.
Defective boom cylinder 0.50 to 4.40
Continuous
head pressure sensor V
2 (internal open or short 0.50 to 0.90
Voltage Between F13 (C) and (A) Boom: At Neutral
circuit) V
Boom cylinder head: 2.80 to 3.22
Hydraulic relief V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L71, L72, and F13, and connect T-adapters to
each female side.
3 (wire breakage or Between L72 (female) (16) and F13 (female) (C) Max. 1 z
defective contact of
Resistance Between L71 (female) (22) and F13 (female) (B) Max. 1 z
connector)
Between L71 (female) (4) and F13 (female) (A) Max. 1 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L72 and F13, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and L72 (female) (16) or F13
circuit) Resistance (female) (C) Min. 1 Mz
WA470-7 40-633
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Troubleshooting by failure code (Display of code)
40-634 WA470-7
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Troubleshooting by failure code (Display of code)
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor (WA470_7-
DHT1KX-400-A-Z0-A)
Action level Failure code Out of Range of Transmission Cut Off Pressure Sensor
Failure
L01 DHT1KX (Transmission controller system)
• Due to open circuit or ground fault in transmission cut-off pressure sensor system,
Detail of transmission cut-off pressure signal voltage is lower than the normal range.
failure (Transmission cut-off pressure sensor signal voltage: Max. 0.3 V)
• Turns off transmission cut-off function.
Action of • Disables change of transmission cut-off setting.
controller • If cause of transmission cut-off failure disappears, machine becomes normal by itself.
Problem on • Transmission cut-off indicator goes out.
machine • Transmission cut-off function does not work.
• Input voltage from transmission cut-off pressure sensor can be checked with monitoring
function.
(Code: 41202 Brake Oil Press Sensor Volt)
Related • Oil pressure sensed by transmission cut-off pressure sensor can be checked with
information monitoring function.
(Code: 41201. Brake Oil Pressure)
• Method of reproducing failure code:Turn starting switch ON and turn transmission cut-off
switch ON.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DBE6KX] is also displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
1 system of transmission 2. Disconnect connector R73 and connect T-adapter to female side.
cut-off pressure sensor 3. Turn starting switch to ON position.
Power
Voltage Between R73 (female) (B) and (A)
supply input 20 to 30 V
a
Replace sensor and check whether failure code disappears.
1.
Turn starting switch to OFF position.
2.
Insert T-adapter into connector R73.
3.
Start engine.
Defective transmission 4.
Turn transmission cut-off switch ON.
cut-off pressure sensor When brake is released 0.9 to 1.1 V
2 (internal open or short When brake pedal is
circuit) Voltage Between R73 (C) and (A) depressed (both right 1.1 to 5.1 V
and left)
Continuous 0.9 to 5.1 V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L61 and R73, and connect T-adapters to each
harness female side.
3 (wire breakage or a Open circuit of 5 V circuit
defective contact of Between L61 (female) (13) and R73 (female) (C) Max. 1 z
connector)
Resistance Between L61 (female) (16) and R73 (female) (B) Max. 1 z
Between L61 (female) (4) and R73 (female) (A) Max. 1 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L61 and R73, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and L61 (female) (13) or R73
circuit) Resistance (female) (C) Min. 1 Mz
WA470-7 40-635
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Troubleshooting by failure code (Display of code)
40-636 WA470-7
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Troubleshooting by failure code (Display of code)
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor (WA470_7-
DHT5KX-400-A-Z0-A)
Action level Failure code Out of Range of Torque Converter Input Pressure Sensor
Failure
L01 DHT5KX (Transmission controller system)
Detail of • Voltage of signal circuit of torque converter input pressure sensor drops below 0.5 V or
failure increases above 4.5 V.
Action of • Controls it by fixing torque converter input pressure to set pressure stored in controller.
controller
Problem on • Large shocks are made when torque converter lockup clutch is engaged.
machine
• Input voltage from torque converter input pressure sensor can be checked with monitoring
function.
(Code: 32602 T/C In. Oil Press Sensor Volt)
Related • Oil pressure sensed by torque converter input pressure sensor can be checked with
information monitoring function.
(Code: 32601 T/C Input Oil Pressure)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DBE6KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective sensor power 2. Disconnect connector TCIN.P, and connect T-adapter to female side.
1 supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 5.
Power
Voltage Between TCIN.P (female) (B) and (A)
supply input 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L61 and TCIN.P, and connect T-adapter to either
Ground fault in wiring female side.
2 3. Disconnect connector TCIN.P, and connect T-adapter to female side.
harness
Between ground and L61 (female) (7) or TCIN.P
Resistance (female) (C) Min. 1 Mz
WA470-7 40-637
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Troubleshooting by failure code (Display of code)
40-638 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-639
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-640 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-641
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-642 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit (WA470_7-
DHT8KB-400-A-Z0-A)
Action level Failure code Steering Pump Pressure Sensor Short Circuit
Failure
L01 DHT8KB (Work equipment controller system)
• Due to hot short in steering pump pressure sensor system, steering pump pressure
Detail of sensor signal voltage is higher than the normal range.
failure (Steering pump pressure sensor signal voltage: Min. 4.7 V)
Action of • Operates, assuming steering pump pressure to be 0 MPa.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine does not pick up normally at the low engine speed.
machine
• Input voltage from steering pump pressure sensor can be checked with monitoring
function.
(Code: 95303 Steering Pump Pres. Sensor Volt)
Related • Oil pressure sensed by steering pump pressure sensor can be checked with monitoring
information function.
(Code: 95302 Steering Pump Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
1 system of steering 2. Disconnect connector R86 and connect T-adapter to female side.
pump pressure sensor 3. Turn starting switch to ON position.
Power 5.00 to 5.20
Voltage Between R86 (female) (3) and (1)
supply input V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R86.
3. Start engine and operate steering.
Defective steering 0.50 to 4.5
pump pressure sensor Continuous
V
2 (internal open or short
Voltage Between R86 (2) and (1) Steering: At Neutral 0.50 to 0.90
circuit) V
Steering: At Relief 3.02 to 3.42
V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector R86 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(contact with 24V
circuit) Voltage Between R86 (female) (2) and ground Max 1 V
If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
Defective work 3. Start engine and operate steering.
4 equipment controller 0.50 to 4.5
Continuous
V
Between L71 (3) and 0.50 to 0.90
Voltage Steering: At Neutral
ground V
Steering: At Relief 3.02 to 3.42
V
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40-644 WA470-7
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Troubleshooting by failure code (Display of code)
WA470-7 40-645
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-646 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-647
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Action level Failure code Emergency Steering Pressure Sensor Short Circuit
Failure
L01 DHUDKB (Work equipment controller system)
• Due to hot short in emergency steering pump pressure sensor system, emergency
Detail of steering pump pressure sensor signal voltage is higher than the normal range.
failure (Emergency steering pump pressure sensor signal voltage: Min. 4.7 V)
Action of • Judges that no emergency steering pump pressure is applied.
controller • If cause of failure disappears, machine becomes normal by itself.
• Emergency steering self-check ends abnormally.
Problem on • Emergency steering operation indicator does not light up while emergency steering is in
machine operation.
• Only for the machine equipped with emergency steering (optional).
• Input voltage from emergency steering pump pressure sensor can be checked with
monitoring function.
(Code: 07705 Emrg. Steering Pres. S. Volt)
Related • Oil pressure sensed by emergency steering pump pressure sensor can be checked with
information monitoring function.
(Code: 07703 Emrg. Steering Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply
system of emergency 1. Turn starting switch to OFF position.
1
steering pump pressure 2. Disconnect connector R37 and connect T-adapter to female side.
sensor 3. Turn starting switch to ON position.
Power 5.00 to 5.20
Voltage Between R37 (female) (3) and (1)
supply input V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R37.
3. Start engine.
4. Turn emergency steering ON and operate steering.
Defective emergency
0.50 to 4.5
steering pump pressure Continuous
V
2 sensor
When emergency 0.50 to 0.90
(internal open or short Voltage Between R37 (2) and (1) steering is stopped V
circuit)
When emergency
steering is turned ON 0.50 to 3.05
and steering is operated V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector R37 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(contact with 24V
circuit) Voltage Between R37 (female) (2) and ground Max 1 V
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WA470-7 40-649
40 Troubleshooting
Troubleshooting by failure code (Display of code)
• Signal from fuel level sensor can be checked with monitoring function. (code: 04200 (V),
Related 04201 (z))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R33 and connect T-adapters to male side.
Defective fuel level
1 Between Fuel level: Full Max. 12 z
sensor
Resistance R33 (male)
(1) and (2) Fuel level: Empty 80 to 100 z
1. Turn starting switch to OFF position.
2. Disconnect connector R33, and connect T-adapters to female side.
Open circuit, short 3. Turn starting switch to ON position.
circuit, ground fault, hot
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
monitor controller this point.
Voltage Between R33 (female) (1) and (2) Approx. 3.3
V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector MCM1 A, and connect T-adapters to female side.
3 wiring harness Between Fuel level: Full Max. 12 z
MCM1 A
Resistance (female) (8)
Fuel level: Empty 80 to 100 z
and (9)
a If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and R33, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of Between MCM1 A (female) (8) and R33 (female)
(1) Max. 1 z
connector) Resistance
Between MCM1 A (female) (9) and R33 (female)
(2) Max. 1 z
Defective monitor If no failure is found by above checks, monitor controller may be defective.
5 (Since this is an internal defect, troubleshooting cannot be performed).
controller
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WA470-7 40-651
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40-652 WA470-7
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Troubleshooting by failure code (Display of code)
WA470-7 40-653
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-654 WA470-7
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Troubleshooting by failure code (Display of code)
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit (WA380_7-
DK55KY-400-A-Z0-A)
Action level Failure code Hot Short of FNR Lever Potentiometer Circuit
Failure
L01 DK55KY (Transmission controller system)
• Due to hot short circuit in directional (FNR) lever analog signal system, analog signal
Detail of voltage from directional (FNR) lever is higher than normal range. (Signal voltage from
failure FNR lever potentiometer: Above 3.8 V)
• Judges that the lever position to be determined from analog signal is N (Neutral).
Action of • Continues to take it that lever position to be determined from analog signal is N (Neutral)
controller until it receives analog signal showing lever position of N (Neutral), even if cause of failure
disappears.
Problem on • No particular problem occurs, as long as directional (FNR) lever switch is normal.
machine
• Analog signal input voltage from directional (FNR) lever can be checked with monitoring
Related function. (Code: 91105 Shift lever Volt)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DBE5KX] is also displayed, perform troubleshooting for it first.
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40-656 WA470-7
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WA470-7 40-657
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-658 WA470-7
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Troubleshooting by failure code (Display of code)
WA470-7 40-659
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-660 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) (WA470_7-
DK59KY-400-A-Z0-A)
Action level Failure code Hot Short of Boom Lever Potentiometer (Main)
Failure
L03 DK59KY (Work equipment controller system)
• Controller determines that boom lever potentiometer (main: A line) circuit has hot short
Detail of because signal voltage from boom lever potentiometer (main: A line) is higher than normal
failure range.
(Signal voltage from boom lever potentiometer (main: A line): Min. 4.7 V)
• Controls boom by using signal voltage from boom lever potentiometer (sub: B line) if it is
normal.
However, in this case, bucket detent control does not work, and work equipment speed
Action of
decreases 30%.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until boom lever is
set in NEUTRAL.
• Boom rises momentarily, then it is controlled normally by using signals from sub
Problem on potentiometer.
machine However, in this case, bucket detent control does not work, and work equipment speed
decreases 30%.
• Input voltage from boom lever potentiometer (main: A line) can be checked with
monitoring function.
(Code: 42000 Boom Lever Volt(Main))
Related • Input voltage from boom lever potentiometer (sub: B line) can be checked with monitoring
information function.
(Code: 42001 Boom Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L28A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L28A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L28A, and connect T-adapter to male side.
Between L28A (male) (1) and ground
Between L28A (male) (2) and ground
Resistance Min. 1 Mz
Between L28A (male) (3) and ground
Defective boom lever
Between L28A (male) (4) and ground
2 potentiometer (internal
short circuit) 3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L28A.
5. Set work equipment lock switch to LOCK position.
6. Turn starting switch to ON position.
7. Operate boom lever to perform troubleshooting.
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WA470-7 40-663
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-664 WA470-7
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Troubleshooting by failure code (Display of code)
WA470-7 40-665
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-666 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-667
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-668 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-669
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-670 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) (WA470_7-
DK5AKY-400-A-Z0-A)
Action level Failure code Hot Short of Boom Lever Potentiometer (Sub)
Failure
L03 DK5AKY (Work equipment controller system)
• Due to hot short in boom lever potentiometer (Sub: B line) system, boom lever
Detail of potentiometer (Sub: B line) signal voltage is higher than the normal range (Boom lever
failure potentiometer (Sub: B line) signal voltage: Min. 4.7 V).
• Controls boom by using signal voltage from boom lever potentiometer (main: A line) if it is
normal.
However, in this case, bucket detent control does not work, and work equipment speed
Action of
decreases 30%.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until boom lever is
set in NEUTRAL.
Problem on • Boom detent control does not work.
machine • Work equipment speed decreases 30%.
• Input voltage from boom lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42000 Boom Lever Volt(Main))
Related • Input voltage from boom lever potentiometer (sub: B line) can be checked with monitoring
information function. (Code: 42001 Boom Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L28A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L28A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L28A, and connect T-adapter to male side.
Between L28A (male) (1) and ground
Between L28A (male) (2) and ground
Resistance Min. 1 Mz
Between L28A (male) (3) and ground
Between L28A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L28A.
5. Set work equipment lock switch to LOCK position.
6. Turn starting switch to ON position.
Defective boom lever 7. Operate boom lever to perform troubleshooting.
2 potentiometer (internal
short circuit) 2.38 to 2.62
Boom lever: NEUTRAL
V
Boom lever: RAISE (just
before the detent 0.96 to 1.62
position) V
Boom lever: RAISE (at 0.60 to 1.10
Between L28A (4) and
Voltage detent position) V
(2)
Boom lever: LOWER
(just before the detent 3.38 to 4.04
position) V
3.90 to 4.40
Boom lever: FLOAT V
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WA470-7 40-673
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40-674 WA470-7
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WA470-7 40-675
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Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) (WA470_7-
DK5BKY-400-A-Z0-A)
Action level Failure code Hot Short of Bucket Lever Potentiometer (Main)
Failure
L03 DK5BKY (Work equipment controller system)
• Due to hot short circuit of bucket lever potentiometer (main: A line) system, signal voltage
Detail of from bucket lever potentiometer (main: A line) is higher than normal range.
failure (Signal voltage from bucket lever potentiometer (main: A line): Min. 4.7 V)
• Controls bucket by using signal voltage from bucket lever potentiometer (sub: B line) if it is
normal.
In this case, however, bucket detent control does not work, and work equipment speed
Action of
decreases to 30% of normal speed.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until bucket lever is
set in NEUTRAL.
• Bucket tilts momentarily, then it is controlled normally by using signals from sub
Problem on potentiometer.
machine In this case, however, bucket detent control does not work, and work equipment speed
decreases to 30% of normal speed.
• Input voltage from bucket lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42002 Bucket Lever Volt(Main))
Related • Input voltage from bucket lever potentiometer (sub: B line) can be checked with
information monitoring function. (Code: 42003 Bucket Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
When failure code [DB96KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L29A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L29A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L29A, and connect T-adapter to male side.
Between L29A (male) (1) and ground
Between L29A (male) (2) and ground
Resistance Min. 1 Mz
Between L29A (male) (3) and ground
Between L29A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L29A.
5. Set work equipment lock switch to LOCK position.
Defective bucket lever
2 potentiometer (internal 6. Turn starting switch to ON position.
short circuit) 7. Operate bucket lever to perform troubleshooting.
2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
before the detent 3.38 to 4.04
position) V
Between L29A (3) and
Voltage
(2) Bucket lever: TILT (at 3.90 to 4.40
detent position) V
0.60 to 1.10
Bucket lever: Full DUMP V
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WA470-7 40-679
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40-680 WA470-7
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WA470-7 40-681
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40-682 WA470-7
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WA470-7 40-683
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40-684 WA470-7
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WA470-7 40-685
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40-686 WA470-7
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Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) (WA470_7-
DK5CKY-400-A-Z0-A)
Action level Failure code Hot Short of Bucket Lever Potentiometer (Sub)
Failure
L03 DK5CKY (Work equipment controller system)
• Controller determines that bucket lever potentiometer (sub: B line) circuit has hot short
Detail of because signal voltage from bucket lever potentiometer (sub: B line) is higher than normal
failure range. (Signal voltage from bucket lever potentiometer (sub: B line): Min. 4.7 V)
• Controls bucket by using signal voltage from bucket lever potentiometer (main: A line) if it
is normal.
However, in this case, bucket detent control does not work, and work equipment speed
Action of
decreases 30 %.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until bucket lever is
set in NEUTRAL.
Problem on • Bucket detent control does not work.
machine • Work equipment speed decreases 30 %.
• Input voltage from bucket lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42002 Bucket Lever Volt(Main))
Related • Input voltage from bucket lever potentiometer (sub: B line) can be checked with
information monitoring function. (Code: 42003 Bucket Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
When failure code [DB96KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L29A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L29A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L29A, and connect T-adapter to male side.
Between L29A (male) (1) and ground
Between L29A (male) (2) and ground
Resistance Min. 1 Mz
Between L29A (male) (3) and ground
Between L29A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L29A.
5. Set work equipment lock switch to LOCK position.
Defective bucket lever
2 potentiometer (internal 6. Turn starting switch to ON position.
short circuit) 7. Operate bucket lever to perform troubleshooting.
2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
before the detent 0.96 to 1.62
position) V
Between L29A (4) and
Voltage
(2) Bucket lever: TILT (at 0.60 to 1.10
detent position) V
3.90 to 4.40
Bucket lever: Full DUMP V
WA470-7 40-687
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-688 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-689
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-690 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-691
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-692 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) (WA470_7-DK5DKY-
400-A-Z0-A)
Action level Failure code Hot Short of 3rd Lever Potentiometer (Main)
Failure
L03 DK5DKY (Work equipment controller system)
• Controller determines that 3rd (attachment) lever potentiometer (main: A line) circuit has
Detail of hot short because signal voltage from 3rd (attachment) lever potentiometer (main: A line)
failure is higher than normal range.
(Signal voltage from 3rd (attachment) lever potentiometer (main: A line): Max. 4.7 V)
• Controls attachment by using signals from 3rd (attachment) lever potentiometer (sub: B
line) if 3rd (attachment) lever potentiometer (sub: B line) is normal.
Action of However, in this case, decreases work equipment speed 30 %.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until 3rd
(attachment) lever is set in NEUTRAL.
• Attachment cylinder extends momentarily, then attachment is controlled normally by using
Problem on signals from sub potentiometer.
machine However, work equipment speed decreases 30 %.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment). (If this failure code is displayed on the machine, select "None" for 3rd valve
(attachment) setting on option setting screen of machine monitor.)
Related • Input voltage from 3rd (attachment) lever potentiometer (main: A line) can be checked
information with monitoring function. (Code: 42006 3rd Lever Volt(Main))
• Input voltage from 3rd (attachment) lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42007 3rd Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L30, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L30 (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L30, and connect T-adapters to male side.
Between L30 (male) (1) and ground
Between L30 (male) (2) and ground
Resistance Min. 1 Mz
Between L30 (male) (3) and ground
Between L30 (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L30.
Defective 3rd 5. Set work equipment lock switch to LOCK position.
2 (attachment) lever
potentiometer 6. Turn starting switch to ON position.
7. Operated 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 3.90 to 4.40
Voltage Between L30 (3) and (2) cylinder fully V
3rd (attachment) lever: 0.60 to 1.10
Operated to retract V
cylinder fully
WA470-7 40-693
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-694 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree (WA470_7-
DK5DL8-400-A-Z0-A)
Action level Failure code 3rd Lever Potentiometer (Main & Sub) Disagree
Failure
L03 DK5DL8 (Work equipment controller system)
• Input signals from 3rd (attachment) lever potentiometers (main: A line and sub: B line)
disagree with each other.
(Signal voltage from 3rd (attachment) lever potentiometers (total of main: A line and sub:
B line): Max. 4.65 V) or
Detail of (signals voltage from 3rd (attachment) lever potentiometers (total of main: A line and sub:
failure B line): Min. 5.35 V)
For PCS (type D and G),
(Total of signal voltages from main: A line and sub: B line is 4.58 V or less) or
(Total of signal voltages from main: A line and sub: B line is 5.42 V or above)
• Operates by using potentiometer sensor signal from either main: A line or sub: B line
which shows the standard voltage when lever is in NEUTRAL position.
However, in this case, decreases work equipment speed 30 %.
• Stops output to 3rd EPC solenoid (extension) and 3rd EPC solenoid (retract) if signal
Action of voltages from both main: A line and sub: B line potentiometers show out of the standard
controller voltage when lever is in NEUTRAL position.
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until 3rd
(attachment) lever is set in NEUTRAL.
• If either main: A line or sub: B line potentiometer malfunctions, machine operates normally
Problem on with work equipment speed decreases 30% after lever is once set to NEUTRAL.
machine • If both of main: A line and sub: B line potentiometers malfunction, cylinder that is
controlled by 3rd valve (attachment) does not move.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment). (If this failure code is displayed on the machine, select "None" for 3rd valve
(attachment) setting on option setting screen of machine monitor.)
Related • Input voltage from 3rd (attachment) lever potentiometer (main: A line) can be checked
information with monitoring function. (Code: 42006 3rd Lever Volt(Main))
• Input voltage from 3rd (attachment) lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42007 3rd Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L30, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L30 (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L30, and connect T-adapters to male side.
Between L30 (male) (1) and ground
Between L30 (male) (2) and ground
Resistance Min. 1 Mz
Between L30 (male) (3) and ground
Defective 3rd
Between L30 (male) (4) and ground
2 (attachment) lever
potentiometer 3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L30.
5. Set work equipment lock switch to LOCK position.
6. Turn starting switch to ON position.
7. Operated 3rd (attachment) lever to perform troubleshooting.
WA470-7 40-695
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-696 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-697
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-698 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-699
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-700 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) (WA470_7-DK5EKY-
400-A-Z0-A)
Action level Failure code Hot Short of 3rd Lever Potentiometer (Sub)
Failure
L03 DK5EKY (Work equipment controller system)
• Controller determines that 3rd (attachment) lever potentiometer (sub: B line) circuit has
Detail of hot short because signal voltage from 3rd (attachment) lever potentiometer (sub: B line) is
failure higher than normal range.
(Signal voltage from 3rd (attachment) lever potentiometer (sub: B line): Min. 4.7 V)
• Controls attachment by using signals from 3rd (attachment) lever potentiometer (main: A
line) if it is normal.
Action of However, in this case, decreases work equipment speed 30 %.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until 3rd
(attachment) lever is set in NEUTRAL.
Problem on • Work equipment speed decreases 30 %.
machine
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment). (If this failure code is displayed on the machine, select "None" for 3rd valve
(attachment) setting on option setting screen of machine monitor.)
Related • Input voltage from 3rd (attachment) lever potentiometer (main: A line) can be checked
information with monitoring function. (Code: 42006 3rd Lever Volt(Main))
• Input voltage from 3rd (attachment) lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42007 3rd Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L30, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L30 (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L30, and connect T-adapters to male side.
Between L30 (male) (1) and ground
Between L30 (male) (2) and ground
Resistance Min. 1 Mz
Between L30 (male) (3) and ground
Between L30 (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L30.
Defective 3rd 5. Set work equipment lock switch to LOCK position.
2 (attachment) lever
potentiometer 6. Turn starting switch to ON position.
7. Operated 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 0.60 to 1.10
Voltage Between L30 (4) and (2) cylinder fully V
3rd (attachment) lever: 3.90 to 4.40
Operated to retract V
cylinder fully
WA470-7 40-701
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-702 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-703
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-704 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit (WA470_7-
DKA0KY-400-A-Z0-A)
Action level Failure code Hot Short of Boom Angle Sensor Circuit
Failure
L01 DKA0KY (Work equipment controller system)
Detail of • Due to hot short circuit in boom angle sensor system, signal voltage from boom angle
failure sensor is higher than normal range. (Signal voltage from boom angle sensor: Min. 4.7 V)
• Determines that boom is at lowest position.
• Disables remote positioner function.
• Disables semi-auto digging.
• Disables boom FLOAT detent function when remote positioner LOWER stop function is
Action of
ON, and allows boom FLOAT detent function to work normally when remote positioner
controller
LOWER stop function is OFF.
• Disables boom RAISE detent function.
• Even if cause of failure disappears, machine does not become normal until boom lever is
set in NEUTRAL.
• Remote positioner malfunctions.
Problem on • Semi-auto digging system malfunctions.
machine • Komatsu SmartLoader Logic malfunctions.
• Input voltage from boom angle sensor can be checked with monitoring function.
(Code: 06005 Boom Angle Sensor Volt)
Related • Angle sensed by boom angle sensor can be checked with monitoring function.
information (Code: 06002 Boom Angle)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
WA470-7 40-705
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-706 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-707
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-708 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-709
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-710 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit (WA470_7-
DKA1KY-400-A-Z0-A)
Action level Failure code Hot Short of Bucket Angle Sensor Circuit
Failure
L01 DKA1KY (Work equipment controller system)
Detail of • Due to hot short circuit in bucket angle sensor system, signal voltage from bucket angle
failure sensor is higher than normal range. (Signal voltage from bucket angle sensor: Min. 4.8 V)
• Determines that bell crank angle is at its minimum.
• Disables bucket positioner function.
Action of • Disables semi-auto digging.
controller • Disables bucket detent function.
• If cause of failure disappears, machine becomes normal by itself.
• Bucket positioner malfunctions (does not work).
Problem on • Semi-auto digging system malfunctions (does not work).
machine • Komatsu SmartLoader Logic malfunctions.
• Input voltage from bucket angle sensor can be checked with monitoring function.
(Code: 55601 Bucket Link Angle Sensor Volt)
Related • Angle sensed by bucket angle sensor can be checked with monitoring function.
information (Code: 55600 Bucket Link Angle)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective 5 V sensor power 2. Disconnect connector F32, and connect T-adapter to female side.
1 supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and
after.
Voltage Between F32 (female) (C) and (A) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector F32, and connect T-adapter to male side.
Between F32 (male) (A) and (C) 4 to 6 kz
Resis- Between F32 (male) (A) and ground Min. 1 Mz
tance Between F32 (male) (B) and ground Min. 1 Mz
Defective bucket angle Between F32 (male) (C) and ground Min. 1 Mz
2 sensor
1. Turn starting switch to OFF position.
(internal short circuit) 2. Insert T-adapter into connector F32.
3. Turn starting switch to ON position.
4. Operate bucket lever to perform troubleshooting.
Continuous 2.5 to 4.7 V
Between F32 (B) and
Voltage Full TILT 4.2 to 4.7 V
(A)
Full DUMP 2.5 to 3.0 V
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector F32, and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
harness
Voltage Between F32 (female) (B) and ground Max. 1 V
If no failure is found by above checks, work equipment controller is
defective.
• Reference
1. Turn starting switch to OFF position.
Defective work equipment 2. Insert T-adapter into connector L72.
4 3. Turn starting switch to ON position.
controller
4. Operate bucket lever to perform troubleshooting.
Continuous 2.5 to 4.7 V
Between L72 (36) and
Voltage Full TILT 4.2 to 4.7 V
ground
Full DUMP 2.5 to 3.0 V
WA470-7 40-711
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-712 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-713
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-714 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-715
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-716 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-717
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-718 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-719
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-720 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-721
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-722 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-723
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-724 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-725
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-726 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-727
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-728 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-729
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-730 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-731
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-732 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-733
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-734 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-735
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator (WA470_7-DT20KB-400-
A-Z0-A)
Action level Failure code Ground Fault of Transmission Cut Off Indicator
Failure
L01 DT20KB (Transmission controller system)
Detail of • Controller determines that transmission cut-off indicator lamp circuit has ground fault
failure because output signal is not entered to indicator lamp.
• Stops driving transmission cut-off indicator lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Transmission cut-off indicator lamp does not light up.
machine
Related • Method of reproducing failure code: Start engine and turn transmission cut-off switch to
information ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective transmission 2. Disconnect connector S_RH1, and connect T-adapters to male side.
cut-off indicator lamp
1 (LED) (internal short Between S_RH1 (male) (1) and (2) Min. 1 Mz
circuit) Resistance Between ground and each of S_RH1 (male) (1) and
(2) Min. 1 Mz
40-736 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-737
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. (WA470_7-
DT22KB-400-A-Z0-A)
Action level Failure code Ground Fault of Work Equipment Lock Indicator
Failure
L01 DT22KB (Work equipment controller system)
Detail of • Controller determines that output circuit to lamp built in work equipment lock switch has
failure ground fault because lamp built in work equipment lock switch is not driven.
• None in particular
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Lamp built in work equipment lock switch does not light up.
machine
• Output signal (ON/OFF) to lamp built in work equipment lock switch can be checked with
Related monitoring function. (Code: 03707 BBC Output 1, Work Equipment Lock Ind.)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective indicator lamp 2. Disconnect connector S_RHC, and connect T-adapter to male side.
(LED) of work
1 equipment lock switch Between S_RHC (male) (1) and (2) Min. 1 Mz
(internal short circuit) Resistance Between ground and each of S_RHC (male) (1)
and (2) Min. 1 Mz
40-738 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-739
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-740 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-741
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and F23, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (6) and F23 (female) (1) Max. 1 z
Resistance
Between L73 (female) (3) and F23 (female) (2) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-742 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-743
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-744 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-745
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) (WA470_7-
DW4PKY-400-A-Z0-A)
Action level Failure code Hot Short of Boom EPC Solenoid (Raise)
Failure
L03 DW4PKY (Work equipment controller system)
Detail of • Due to hot short circuit in signal output circuit to boom RAISE EPC solenoid, abnormal
failure voltage appears when controller does not drive boom RAISE EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd (attachment)
EXTEND and RETRACT.
Action of • Stops driving every work equipment detent.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• All work equipment do not move because work equipment neutral lock solenoid is
Problem on energized.
machine • Boom RAISE EPC solenoid may be burnt out.
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
function. (Code: 41900 Boom Raise EPC Current)
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
function. (Code: 41901 Boom Lower EPC Current)
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
function. (Code: 41902 Bucket Tilt EPC Current)
Related • Output current value to bucket DUMP EPC solenoid can be checked with monitoring
information function. (Code: 41903 Bucket Dump EPC Current)
• Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Output current value to 3rd valve (attachment) RETRACT EPC solenoid can be checked
with monitoring function. (Code: 41907 3rd Retract EPC Current)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective boom RAISE 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector F23, and connect T-adapter to male side.
short circuit) Resistance Between F23 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F23 and connect T-adapters to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F23 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F23, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (6) and each No continuity
Continuity
pin other than pin (6) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-746 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-747
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Problem on
• Boom does not lower.
machine
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
Related function. (Code: 41901 Boom Lower EPC Current)
information • Method of reproducing failure code: Start engine and move boom lever to LOWER
position.
No. Cause Procedure, measuring location, criteria and remarks
Defective boom 1. Turn starting switch to OFF position.
1 LOWER EPC solenoid 2. Disconnect connector F24 and connect T-adapter to male side.
(internal open circuit) Resistance Between F24 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector F24, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between F24 (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L73, and connect T-adapter to female side.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L73 (female) (16) and (3) 5 to 15 z
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and F24, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (3) and F24 (female) (2) Max. 1 z
Resistance
Between L73 (female) (16) and F24 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-748 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-749
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-750 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-751
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) (WA470_7-
DW4QKY-400-A-Z0-A)
Action level Failure code Hot Short of Boom EPC Solenoid (Lower)
Failure
L03 DW4QKY (Work equipment controller system)
Detail of • Due to hot short circuit in signal output circuit to boom LOWER EPC solenoid, abnormal
failure voltage appears when controller does not drive boom LOWER EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd valve
(attachment) EXTEND and RETRACT.
Action of • Stops driving every work equipment detent.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• All work equipment do not move because work equipment neutral lock solenoid is
Problem on energized.
machine • Boom LOWER EPC solenoid may be burnt out.
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
function. (Code: 41900 Boom Raise EPC Current)
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
function. (Code: 41901 Boom Lower EPC Current)
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
function. (Code: 41902 Bucket Tilt EPC Current)
Related • Output current value to bucket DUMP EPC solenoid can be checked with monitoring
information function. (Code: 41903 Bucket Dump EPC Current)
• Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Output current value to 3rd valve (attachment) RETRACT EPC solenoid can be checked
with monitoring function. (Code: 41907 3rd Retract EPC Current)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective boom 1. Turn starting switch to OFF position.
1 LOWER EPC solenoid 2. Disconnect connector F24 and connect T-adapter to male side.
(internal short circuit) Resistance Between F24 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F24, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F24 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F24, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (16) and each No continuity
Continuity
pin other than pin (16) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-752 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-753
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and F21, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (3) and F21 (female) (2) Max. 1 z
Resistance
Between L73 (female) (37) and F21 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-754 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-755
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-756 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-757
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) (WA470_7-
DW4RKY-400-A-Z0-A)
Action level Failure code Hot Short of Bucket EPC Solenoid (Tilt)
Failure
L03 DW4RKY (Work equipment controller system)
Detail of • Due to hot short circuit in signal output circuit to bucket TILT EPC solenoid, abnormal
failure voltage appears when controller does not drive bucket TILT EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd valve
(attachment) EXTEND and RETRACT.
Action of • Stops driving every work equipment detent.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• All work equipment do not move because work equipment neutral lock solenoid is
Problem on energized.
machine • Bucket TILT EPC solenoid may be burnt out.
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
function. (Code: 41900 Boom Raise EPC Current)
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
function. (Code: 41901 Boom Lower EPC Current)
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
function. (Code: 41902 Bucket Tilt EPC Current)
Related • Output current value to bucket DUMP EPC solenoid can be checked with monitoring
information function. (Code: 41903 Bucket Dump EPC Current)
• Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Output current value to 3rd valve (attachment) RETRACT EPC solenoid can be checked
with monitoring function. (Code: 41907 3rd Retract EPC Current)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective bucket TILT 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector F21 and connect T-adapter to male side.
short circuit) Resistance Between F21 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F21, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F21 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F21, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (37) and each No continuity
Continuity
pin other than pin (37) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-758 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-759
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and F22, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (3) and F22 (female) (2) Max. 1 z
Resistance
Between L73 (female) (27) and F22 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-760 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-761
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-762 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-763
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) (WA470_7-
DW4SKY-400-A-Z0-A)
Action level Failure code Hot Short of Bucket EPC Solenoid (Dump)
Failure
L03 DW4SKY (Work equipment controller system)
Detail of • Due to hot short circuit in output signal circuit to bucket DUMP EPC solenoid, abnormal
failure voltage appears when controller does not drive bucket DUMP EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd valve
(attachment) EXTEND and RETRACT.
Action of • Stops driving every work equipment detent.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• All work equipment do not move because work equipment neutral lock solenoid is
Problem on energized.
machine • Bucket DUMP EPC solenoid may be burnt out.
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
function. (Code: 41900 Boom Raise EPC Current)
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
function. (Code: 41901 Boom Lower EPC Current)
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
function. (Code: 41902 Bucket Tilt EPC Current)
Related • Output current value to bucket DUMP EPC solenoid can be checked with monitoring
information function. (Code: 41903 Bucket Dump EPC Current)
• Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Output current value to 3rd valve (attachment) RETRACT EPC solenoid can be checked
with monitoring function. (Code: 41907 3rd Retract EPC Current)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective bucket DUMP 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector F22, and connect T-adapter to male side.
short circuit) Resistance Between F22 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connectors F22, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F22 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F22, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (27) and each No continuity
Continuity
pin other than pin (27) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-764 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-765
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and R59, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (23) and R59 (female) (2) Max. 1 z
Resistance
Between L63 (female) (35) and R59 (female) (1) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)
40-766 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-767
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. (WA470_7-
DW7BKB-400-A-Z0-A)
Action level Failure code Ground Fault of Radiator Fan Reverse Solenoid
Failure
L01 DW7BKB (Transmission controller system)
Detail of • Due to ground fault in fan reverse solenoid system, no current flows when controller
failure drives fan reverse solenoid.
• Stops driving fan reverse solenoid.
Action of • Disables reverse rotation of fan.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• Fan cannot rotate in reverse direction.
Problem on
• When this failure occurs with fan rotating in reverse direction, fan rotation direction
machine
switches to normal direction.
• Output current value to fan reverse solenoid can be checked with monitoring function.
Related (Code: 31646 Fan Reverse solenoid Current)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
40-768 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-769
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. (WA470_7-DW7BKY-400-A-
Z0-A)
Action level Failure code Hot Short of Radiator Fan Reverse Solenoid
Failure
L01 DW7BKY (Transmission controller system)
Detail of • Due to hot short circuit in fan reverse solenoid system, abnormal voltage appears when
failure controller does not drive fan reverse solenoid.
• Disables reverse rotation of fan.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Fan does not rotate in normal direction.
machine • Radiator may overheat.
• Output current value to fan reverse solenoid can be checked with monitoring function.
Related (Code: 31646 Fan Reverse solenoid Current)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fan reverse 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector R59 and connect T-adapter to male side.
(internal short circuit) Resistance Between R59 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector R59, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between R59 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and R59, and connect T-adapter to female
side of L63.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L63 (female) (35) and each No continuity
Continuity
pin other than pin (35) (No sound is heard)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)
40-770 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L72 and F31, and connect T-adapters to each
defective contact of female side.
connector) Between F31 (female) (2) and ground Max. 1 z
Resistance
L72 (female) (19) and F31 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
WA470-7 40-771
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-772 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-773
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-774 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-775
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-776 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-777
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-778 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-779
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-780 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-781
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-782 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-783
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-784 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-785
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-786 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-787
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-788 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. (WA470_7-
DX16KA-400-A-Z0-A)
Action level Failure code Disconnection of Radiator Fan Pump EPC Solenoid
Failure
L03 DX16KA (Transmission controller system)
Detail of • Due to open circuit in fan pump EPC solenoid circuit, no current flows when controller
failure drives fan pump EPC solenoid.
• Disables fan to rotate in reverse direction.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Fan rotates at its maximum speed.
Problem on • Fan cannot rotate in reverse direction.
machine • When this failure occurs with fan rotating in reverse direction, fan rotation direction
switches to normal direction.
• Output current value to fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 41400 Rad. Fan Pump EPC Sol. Current)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fan pump 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector R29, and connect T-adapter to male side.
open circuit) Resistance Between R29 (male) (1) and (2) 5 to 10 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R29, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R29 (female) (1) and (2) Min. 20 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector L63, and connect T-adapter to female side.
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L63 (female) (25) and (23) 5 to 10 z
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connectors L61, L62, L63, and R29, and connect T-adapters
to each female side of L61, L62, and L63.
a Check by using multimeter in continuity mode.
Between L63 (female) (25) and each No continuity
pin of L61 (female) (No sound is heard)
Continuity
Between L63 (female) (25) and each No continuity
pin of L62 (female) (No sound is heard)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and R29, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (23) and R29 (female) (2) Max. 1 z
Resistance
Between L63 (female) (25) and R29 (female) (1) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)
WA470-7 40-789
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-790 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. (WA470_7-
DX16KB-400-A-Z0-A)
Action level Failure code Ground Fault of Radiator Fan Pump EPC Solenoid
Failure
L03 DX16KB (Transmission controller system)
Detail of • Due to ground fault in fan pump EPC solenoid circuit, abnormal current flows when
failure controller drives fan pump EPC solenoid.
• Disables fan to rotate in reverse direction.
Action of • Stops driving fan pump EPC solenoid.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• Fan rotates at its maximum speed.
Problem on • Fan cannot rotate in reverse direction.
machine • When this failure occurs with fan rotating in reverse direction, fan rotation direction
switches to normal direction.
• Output current value to fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 41400 Rad. Fan Pump EPC Sol. Current)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective fan pump 2. Disconnect connector R29, and connect T-adapter to male side.
1 EPC solenoid (internal
short circuit) Between R29 (male) (1) and (2) 5 to 10 z
Resistance
Between ground and each of R29 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L63, and connect T-adapter to female side.
wiring harness
Resistance Between L63 (female) (25) and (23) 5 to 10 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and R29, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L63 (female) (25) or R29
circuit) Resistance (female) (1) Min. 1 Mz
WA470-7 40-791
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-792 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. (WA470_7-
DX16KY-400-A-Z0-A)
Action level Failure code Hot Short of Radiator Fan Pump EPC Solenoid
Failure
L01 DX16KY (Transmission controller system)
Detail of • Due to hot short circuit in fan pump EPC solenoid circuit, abnormal voltage appears when
failure controller does not drive fan pump EPC solenoid.
• Disables fan to rotate in reverse direction.
Action of • Stops driving fan pump EPC solenoid.
controller • If cause of failure disappears, machine becomes normal by itself.
• Fan rotates at its minimum speed.
Problem on • Fan cannot rotate in reverse direction.
machine • When this failure occurs with fan rotating in reverse direction, fan rotation direction
switches to normal direction.
• Output current value to fan pump EPC solenoid can be checked with monitoring function.
(Code: 41400 Rad. Fan Pump EPC Sol. Current)
Related • Since female side voltage is 20 V or above when pump EPC solenoid connector is
information disconnected and starting switch is turned to ON position, check of hot short circuit in
wiring harness is not available.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fan pump 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector R29, and connect T-adapter to male side.
short circuit) Resistance Between R29 (male) (1) and (2) 5 to 10 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and R29, and connect T-adapter to female
side of L63.
a Check by using multimeter in continuity mode.
Between L63 (female) (25) and each No continuity
Continuity
pin other than pin (25) (No sound is heard)
Short circuit in wiring 1. Turn starting switch to OFF position.
2
harness 2. Disconnect connectors L61, L62, L63, and R29, and connect T-adapters
to each female side of L61, L62, and L63.
a Check by using multimeter in continuity mode.
Between L63 (female) (25) and each No continuity
pin of L61 (female) (No sound is heard)
Continuity
Between L63 (female) (25) and each No continuity
pin of L62 (female) (No sound is heard)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)
WA470-7 40-793
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-794 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and R71, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (23) and R71 (female) (1) Max. 1 z
Resistance
Between L73 (female) (35) and R71 (female) (2) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
WA470-7 40-795
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-796 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-797
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-798 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid (WA380_7-
DXA1KY-400-A-Z0-A)
Action level Failure code Hot Short of Loader Pump EPC Solenoid
Failure
L01 DXA1KY (Work equipment controller system)
Detail of • Due to hot short circuit in loader pump EPC solenoid power supply system, abnormal
failure voltage appears when controller does not drive loader pump EPC solenoid.
• Stops driving loader pump EPC solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Flow rate of loader pump reaches minimum level, decreasing work equipment speed.
machine
• Output current value to loader pump EPC solenoid can be checked with monitoring
function. (Code: 94500 Loader Pump EPC Current)
Related • Since female side voltage is 20 V or above when pump EPC solenoid connector is
information disconnected and starting switch is turned to ON position, check of hot short circuit in
wiring harness is not available.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective loader pump EPC 2. Disconnect connector R71, and connect T-adapter to male side.
1 solenoid (internal short circuit) Resis-
Between R71 (male) (1) and (2) 5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and R71, and connect T-adapter to
female side of L73.
a Check by using multimeter in continuity mode.
Between L73 (female) (35) and No continuity
Continuity
each pin other than pin (35) (No sound is heard)
WA470-7 40-799
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-800 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-801
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-802 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-803
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-804 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid (WA470_7-
DXANKY-400-A-Z0-A)
Action level Failure code Hot Short of Steering Pump EPC Solenoid
Failure
L01 DXANKY (Work equipment controller system)
Detail of • Due to hot short circuit in steering pump EPC solenoid power supply system, abnormal
failure voltage appears when controller does not drive steering pump EPC solenoid.
• Stops driving steering pump EPC solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Flow rate of steering pump reaches minimum level, decreasing turning speed.
machine
• Output current value to steering pump EPC solenoid can be checked with monitoring
function. (Code: 94600 Steering Pump EPC Current)
Related • Since female side voltage is 20 V or above when pump EPC solenoid connector is
information disconnected and starting switch is turned to ON position, check of hot short circuit in
wiring harness is not available.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective steering 1. Turn starting switch to OFF position.
1 pump EPC solenoid 2. Disconnect connector R90 and connect T-adapter to male side.
(internal short circuit) Resistance Between R90 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L71, L72, L73, and R90, and connect T-adapters
to each female side of L71, L72, and L73.
Short circuit in wiring a Check by using multimeter in continuity mode.
2
harness Between L73 (female) (25) and each No continuity
pin of L71 (female) (No sound is heard)
Resistance
Between L73 (female) (25) and each No continuity
pin of L72 (female) (No sound is heard)
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)
WA470-7 40-805
40 Troubleshooting
Troubleshooting by failure code (Display of code)
• Output current value to lockup clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31609 ECMV Current (Lockup))
information • Method of reproducing failure code: Start engine, turn on lockup switch, and drive
machine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective lockup clutch 2. Disconnect connector LC.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between LC.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector LC.PS, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between LC.PS (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector L63, and connect T-adapter to female side.
Resistance Between L63 (female) (36) and (23) 5 to 15 z
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and LC.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (36) and LC.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (23) and LC.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller
40-806 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-807
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-808 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-809
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-810 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-811
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and 1.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (27) and 1.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (13) and 1.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller
40-812 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-813
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-814 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-815
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-816 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-817
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and 2.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (37) and 2.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (3) and 2.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller
40-818 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-819
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-820 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-821
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-822 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-823
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and 3.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (6) and 3.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (3) and 3.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller
40-824 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-825
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-826 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-827
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-828 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-829
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and R.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (5) and R.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (13) and R.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller
40-830 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-831
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-832 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-833
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-834 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-835
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-836 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-837
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-838 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-839
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-840 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-841
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-842 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-843
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-844 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-845
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-846 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-847
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-848 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-849
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) (WA380_7-
DXHJKB-400-A-Z0-A)
Action level Failure code Ground Fault of 3rd EPC Solenoid (Extension)
Failure
L03 DXHJKB (Work equipment controller system)
• Due to ground fault in signal output circuit to 3rd valve (attachment) EXTEND EPC
Detail of
solenoid, abnormal current flows when controller drives 3rd valve (attachment) EXTEND
failure
EPC solenoid.
• Stops driving 3rd valve (attachment) EXTEND EPC solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not extend.
machine • Wiring harness or controller may be burnt out.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
If this failure code is displayed on the machine that is not equipped with 3rd valve
(attachment), select "None" for 3rd (attachment) lever setting on option setting screen of
Related machine monitor.
information • Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 3rd valve 2. Disconnect connector F25, and connect T-adapter to male side.
1 (attachment) EXTEND EPC Between F25 (male) (1) and (2) 5 to 15 z
solenoid (internal short circuit) Resis- Between ground and each of F25 (male) (1) and
tance Min. 1 Mz
(2)
1. Turn starting switch to OFF position.
2. Disconnect connector L73, and connect T-adapter to female side.
Open or short circuit in wiring
2 a Coil resistance of solenoid
harness
Resis- Between L73 (female) (26) and (3)
5 to 15 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors L73 and F25, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and L73 (female) (26) or F25
Min. 1 Mz
tance (female) (1)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors L73 and F25, and connect T-adapter to
either female side.
Resis- Between L73 (female) (26) and (3), or between
Min. 1 Mz
tance F25 (female) (1) and (2)
If no failure is found by above checks, work equipment controller may
Defective work equipment be defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)
40-850 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-851
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) (WA380_7-DXHJKY-400-
A-Z0-A)
Action level Failure code Hot Short of 3rd EPC Solenoid (Extension)
Failure
L03 DXHJKY (Work equipment controller system)
• Due to hot short circuit in output signal circuit to 3rd valve (attachment) EXTEND EPC
Detail of
solenoid, abnormal voltage appears when controller does not drive 3rd valve (attachment)
failure
EXTEND EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER EPC solenoids, bucket TILT and DUMP EPC
solenoids, 3rd valve (attachment) EXTEND and RETRACT EPC solenoids, and 4th valve
Action of (attachment) EXTEND and RETRACT EPC solenoids.
controller • Stops driving every work equipment detent.
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not extend.
machine • 3rd valve (attachment) EXTEND EPC solenoid may be burnt.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
If this failure code is displayed on the machine, select "None" for 3rd (attachment) lever
Related setting on option setting screen of machine monitor.
information • Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective 3rd valve 1. Turn starting switch to OFF position.
(attachment) EXTEND 2. Disconnect connector F25, and connect T-adapter to male side.
1 EPC solenoid (internal
short circuit) Resistance Between F25 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F25, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F25 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F25, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (26) and each No continuity
Continuity
pin other than pin (26) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-852 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-853
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-854 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-855
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) (WA380_7-
DXHKKB-400-A-Z0-A)
Action level Failure code Ground Fault of 3rd EPC Solenoid (Retract)
Failure
L03 DXHKKB (Work equipment controller system)
• Due to ground fault in output signal circuit to 3rd valve (attachment) retract EPC solenoid,
Detail of
abnormal current flows when controller drives 3rd valve (attachment) retract EPC
failure
solenoid.
• Stops driving 3rd valve (attachment) retract EPC solenoid.
• Stops driving every work equipment detent.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not retract.
machine • Wiring harness or controller may be burnt.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
If this failure code is displayed on the machine that is not equipped with 3rd valve
(attachment), select "None" for 3rd (attachment) lever setting on option setting screen of
Related machine monitor.
information • Output current value to 3rd valve (attachment) retract EPC solenoid can be checked with
monitoring function. (Code: 41907 3rd retract EPC current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 3rd valve 2. Disconnect connector F26, and connect T-adapter to male side.
1 (attachment) Rretract EPC Between F26 (male) (1) and (2) 5 to 15 z
solenoid (internal short circuit) Resis- Between ground and each of F26 (male) (1) and
tance Min. 1 Mz
(2)
1. Turn starting switch to OFF position.
Open or short circuit in wiring2. Disconnect connector L73, and connect T-adapter to female side.
2
harness Resis- Between L73 (female) (36) and (3)
5 to 15 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors L73 and F26, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and L73 (female) (36) or F26
Min. 1 Mz
tance (female) (1)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors L73 and F26, and connect T-adapter to
either female side.
Resis- Between L73 (female) (36) and (3), or between
Min. 1 Mz
tance F26 (female) (1) and (2)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)
40-856 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-857
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) (WA380_7-DXHKKY-
400-A-Z0-A)
Action level Failure code Hot Short of 3rd EPC Solenoid (Retract)
Failure
L03 DXHKKY (Work equipment controller system)
• Due to hot short circuit in output signal circuit to 3rd valve (attachment) retract EPC
Detail of
solenoid, abnormal voltage appears when controller does not drive 3rd valve (attachment)
failure
retract EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER EPC solenoids, bucket TILT and DUMP EPC
solenoids, 3rd valve (attachment) EXTEND and RETRACT EPC solenoids, and 4th valve
Action of (attachment) EXTEND and RETRACT EPC solenoids.
controller • Stops driving every work equipment detent.
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not retract.
machine • 3rd valve (attachment) retract EPC solenoid may be burnt out.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
If this failure code is displayed on the machine, select "None" for 3rd (attachment) lever
Related setting on option setting screen of machine monitor.
information • Output current value to 3rd valve (attachment) retract EPC solenoid can be checked with
monitoring function. (Code: 41907 3rd Retract EPC Current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective 3rd valve 1. Turn starting switch to OFF position.
(attachment) retract 2. Disconnect connector F26, and connect T-adapter to male side.
1 EPC solenoid (internal
short circuit) Resistance Between F26 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F26, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F26 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F26, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (36) and each No continuity
Continuity
pin other than pin (36) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)
40-858 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-859
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-860 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-861
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-862 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-863
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-864 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-865
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-866 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-867
40 Troubleshooting
Troubleshooting by failure code (Display of code)
40-868 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)
WA470-7 40-869
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-870 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-871
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-872 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-873
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-874 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-875
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-876 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-877
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-878 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-879
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-880 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-881
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-882 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display
nothing (WA470_7-FH7-400-A-Z0-A)
Failure All of LCD unit, LED unit, and meter unit on machine monitor display nothing.
• Display of rearview monitor is normal.
Related
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
information
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
Incorrect operation of
1 battery disconnect Check that battery disconnect switch is at ON position.
switch
Incorrect operation of
2 engine shutdown Check that engine shutdown secondary switch is at lower (OFF) position.
secondary switch
Defective slow-blow If slow-blow fuse is blown out, circuit probably has ground fault. In this case,
3 perform check on cause 8 first.
fuse
Defective fuse 1 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 8.)
4
box 2
Defective fuses 3 and If fuse is blown, circuit may have ground fault. (See check on cause 8.)
5
15 in fuse box 2
Defective continuous
6 Perform troubleshooting for failure code [DAF3KK].
power supply system
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MCM1 A, and connect T-adapters to female side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
a Check that engine shutdown secondary switch is at lower (OFF) position.
Between MCM1 A (female) (43) and (2) 20 to 30 V
Voltage Between MCM1 A (female) (31) and (2) 20 to 30 V
Between MCM1 A (female) (24) and (3) 20 to 30 V
Open circuit in wiring
harness a If no failure is found by above checks, this check is not required.
7 (wire breakage or 1. Check that system operating lamp does not light up, and then set battery
defective contact of disconnect switch to OFF position.
connector) 2. Turn starting switch to OFF position.
3. Disconnect connectors MCM1 A and S_FS, and connect T-adapters to
each female side.
Between MCM1 A (female) (24) and (43) Max. 1 z
Between MCM1 A (female) (24) and S_FS (female)
(2) Max. 1 z
Between MCM1 A (female) (31) and S_FS (female)
Max. 1 z
Resistance (1)
Between S_FS (female) (1) and (4) Max. 1 z
Between S_FS (female) (2) and (5) Max. 1 z
Between S_FS (female) (2) and terminal ACC of Max. 1 z
starting switch
WA470-7 40-883
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Ground fault in wiring a For FS9, see circuit diagram for E-4.
harness Between ground and MCM1 A (female) (1), (4), or
8 Min. 1 Mz
(contact with ground FS9-3
circuit) Between ground and MCM1 A (female) (24), (43),
Min. 1 Mz
Resistance or FS9-15
Between MCM1 A (female) (31) and ground Min. 1 Mz
Between FS9-1 (both terminals) and ground Min. 1 Mz
Between FS9-15 (both terminals) and ground Min. 1 Mz
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Defective starting 3. Disconnect cable from terminal B of starting switch.
9 switch (internal defect) Between starting switch Starting switch: OFF Min. 1 Mz
terminals B and ACC
Resistance
Between starting switch Starting switch: ON Max. 1 z
terminals B and ACC
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
10 this is an internal defect, troubleshooting cannot be performed.)
controller
40-884 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-885
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-886 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Wiring harness between monitor controller and LCD unit of machine monitor
Circuit diagram between monitor controller and LCD unit of machine monitor
WA470-7 40-887
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-888 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Wiring harness between monitor controller and LCD unit of machine monitor
Circuit diagram between monitor controller and LCD unit of machine monitor
WA470-7 40-889
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-890 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Wiring harness between monitor controller and LCD unit of machine monitor
Circuit diagram between monitor controller and LCD unit of machine monitor
WA470-7 40-891
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-892 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Wiring harness between monitor controller and meter unit of machine monitor
WA470-7 40-893
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Circuit diagram between monitor controller and meter unit of machine monitor
40-894 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-895
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Wiring harness between monitor controller and meter unit of machine monitor
40-896 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Circuit diagram between monitor controller and meter unit of machine monitor
WA470-7 40-897
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Failure LED unit lamp of machine monitor does not light up, or does not go out.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related information
a Machine monitor connector MDM2 is a 070 type connector with 6 pins, and T-
adapter for this connector is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to LED unit of
machine monitor and connector of monitor controller, and repeat
1 Defective harness connector
connection and disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
Display abnormality record in the service mode of machine monitor. If
Defective LIN communication failure code [DPQ2KR] of action level L01 is logged, perform
2
line troubleshooting for failure code [DPQ2KR].
Display abnormality record in the service mode of machine monitor. If
Defective 12 V power supply
3 failure code [DAFDKB] of action level L01 is logged, perform
system
troubleshooting for failure code [DAFDKB].
a When using T-adapter for connector MDM2 (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MDM2, and connect T-adapters to female
side.
Open circuit in wiring harness 4. Turn battery disconnect switch to ON position.
4 (wire breakage or defective 5. Turn starting switch to ON position.
contact of connector) Between MDM2 (female) (1) and (2) 9.3 to 14.1
a 12 V power supply V
Between MDM2 (female) (3) and (2)
Voltage Approx. 9 V
a LIN communication line
Between MDM2 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply
If no failure is found by check on cause 4, LED unit of machine monitor
is defective.
Defective LED unit of machine
5 a When not using T-adapter for connector MDM2 (070-6), if no failure
monitor
is found by checks on causes 2 and 3, replace LED unit of machine
monitor to check whether LED unit is defective.
If no failure is found by above checks, monitor controller may be
6 Defective monitor controller
defective.
If you cannot perform check on cause 4 for some reason, take it that
7 Defective wiring harness
wiring harness is defective.
40-898 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Wiring harness between monitor controller and LED unit of machine monitor
Circuit diagram between monitor controller and LED unit of machine monitor
WA470-7 40-899
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-900 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Wiring harness between monitor controller and switch panel of machine monitor
Circuit diagram between monitor controller and switch panel of machine monitor
WA470-7 40-901
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-902 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Wiring harness between monitor controller and switch panel of machine monitor
WA470-7 40-903
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Circuit diagram between monitor controller and switch panel of machine monitor
40-904 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Failure Switch panel buzzer of machine monitor does not sound or does not stop sounding.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related information
a Machine monitor connector MOM1 is a 070 type connector with 6 pins, and T-
adapter for this connector is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to switch
panel of machine monitor and connector of monitor controller, and
1 Defective harness connector
repeat connection and disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
Display abnormality record in the service mode of machine monitor. If
Defective LIN communication failure code [DPQ1KR] of action level L01 is logged, perform
2
line troubleshooting for failure code [DPQ1KR].
Display abnormality record in the service mode of machine monitor. If
Defective 12 V power supply
3 failure code [DAFDKB] of action level L01 is logged, perform
system
troubleshooting for failure code [DAFDKB].
a When using T-adapter for connector MOM1 (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MOM1, and connect T-adapters to female
side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Open circuit in wiring harness Between MOM1 (female) (1) and (2) 9.3 to 14.1
4 (wire breakage or defective a 12 V power supply V
contact of connector)
Between MOM1 (female) (3) and (2)
Approx. 9 V
a LIN communication line
Voltage Between MOM1 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply
Between MOM1 When turning on
(female) (6) and (2) Max. 0.2 V
buzzer
Between MOM1 When turning off
(female) (6) and (2) 7 to 15 V
buzzer
If no failure is found by check on cause 4, switch panel of machine
monitor is defective.
Defective switch panel of
5 a When not using T-adapter for connector MOM1 (070-6), if no failure
machine monitor
is found by checks on causes 2 and 3, replace switch panel of
machine monitor to check whether switch panel is defective.
If no failure is found by above checks, monitor controller may be
6 Defective monitor controller
defective.
If you cannot perform check on cause 4 for some reason, take it that
7 Defective wiring harness
wiring harness is defective.
WA470-7 40-905
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Wiring harness between monitor controller and switch panel of machine monitor
Circuit diagram between monitor controller and switch panel of machine monitor
40-906 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-15 Rear view monitor does not light up or backlight flickers (WA380_7-FHH-400-A-
Z0-A)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (RVM1) of wiring harness connected to
rearview monitor, and repeat connection and disconnection of
2 Defective harness connector
connector.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RVM1, and connect T-adapters to female
side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between RVM1 (female) (1) and (2) 20 to 30 V
Voltage
Open circuit in wiring harness Between RVM1 (female) (12) and (2) 20 to 30 V
3 (wire breakage or defective 1. Check that system operating lamp does not light up, and then set
contact of connector) battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RVM1 and S_FS, and connect T-adapters to
each female side.
4. Remove fuse 3 in fuse box 2 (FS9).
Between RVM1 (female) (1) and FS9-3 Max. 1 z
Resis- Between RVM1 (female) (2) and ground Max. 1 z
tance Between RVM1 (female) (12) and S_FS
(female) (4) Max. 1 z
WA470-7 40-907
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-908 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-909
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-16 Rear view monitor images are not displayed clearly (WA380_7-FHJ-400-A-Z0-A)
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Insert T-adapter into connector RVM1.
4. Disconnect connector RVM2 and connect T-adapters to male side.
Defective rearview 5. Turn battery disconnect switch to ON position.
3
monitor 6. Turn starting switch to ON position.
Between RVM2 (male) (1) and RVM1 (2) 8 ± 0.8 V
Voltage Between RVM2 (male) (5) and RVM1 (2) Max. 0.2 V
Between RVM2 (male) (8) and RVM1 (2) Max. 0.2 V
40-910 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-911
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-912 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-913
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-914 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-915
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-916 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-917
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-19 Some items of gauges and caution lamps on machine monitor are
not displayed properly (WA500_7-FHP-400-A-Z0-A)
Failure Some gauges and caution lamps are not displayed normally.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause Procedure, measuring location, criteria and remarks
Perform troubleshooting for failure code related to defective sensor or
1 Defective sensor or switch
switch.
Defective CAN communication Perform troubleshooting for failure code related to defective CAN
2 system communication.
If no failure is found by above checks, machine monitor is defective.
3 Defective machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)
40-918 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-20 Parking brake indicator lamp does not light when the parking brake
is set to ON (Parking) position (WA500_7-HP6-400-A-Z0-A)
k Be sure to chock the wheels. When performing troubleshooting with parking brake released, be
sure to depress foot brake pedal (two persons required for this work).
• Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position.
• Short circuit or ground fault of parking brake indicator switch circuit
Failure • The parking brake detector circuit (MCM1 A (71 pin)) is at GND level even when the
parking brake switch is operated.
• The parking brake does not apply.
• If normal, the parking brake indicator (oil pressure) switch turns OFF when the parking
brake switch is set to ON (Parking) because oil pressure will not act on the switch.
• When 24 V is applied to parking brake solenoid, parking brake is released.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related • For operation of parking brake relay (L120), see failure code [2F00MA].
information • Make sure that fuse No. 3 of fuse box 1 is not blown.
• Input signal (ON/OFF) from the parking brake indicator switch can be checked with
monitoring function (Code: 04510 Parking Brake Press SW).
• Input signal (ON/OFF) (neutralizer signal) from the parking brake switch can be checked
with monitoring function (Code: 02215 Parking Brake Switch).
• See E-33.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Interchange relay L120 with horn relay L119.
Defective parking brake relay 3. Turn starting switch to ON position.
1 (L120) 4. Turn the parking brake switch to the Parking position.
5. Start engine.
• If parking brake indicator lamp lights up, original relay L120 is
defective.
• When failure code [D1E6KA], [D1E6KB] or [D1E6KY] is displayed,
perform troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Interchange relay L133 with horn relay L119.
Defective auto-idle stop
2 3. Turn starting switch to ON position.
parking brake relay L133
4. Turn the parking brake switch to the Parking position.
5. Start engine.
• If parking brake indicator lamp lights up, original relay L133 is
defective.
1. Turn starting switch to OFF position.
Defective parking brake 2. Disconnect connector PB.SW and connect T-adapters to female
indicator switch side.
3
Between PB.SW (male) (1) and (2) Min. 1 Mz
(internal short circuit) Resis-
Between ground and each of PB.SW
tance Min. 1 Mz
(male) (1) and (2)
WA470-7 40-919
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-920 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-921
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-922 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-21 When brake accumulator oil pressure drops, the brake oil pressure
caution lamp does not light (WA470_7-FP7-400-A-Z0-A)
When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
Failure light.
• Short circuit or ground fault of front brake accumulator pressure switch
• If normal, the brake accumulator pressure switch turns OFF when the brake oil pressure
drops.
Related • When front brake accumulator oil pressure drops, the brake oil pressure caution lamp
information does not light.
• Input signal (ON/OFF) from the front brake accumulator pressure switch can be checked
with monitoring function (Code: 04510 "Front Brake Oil Press").
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective front brake 2. Make sure that the brake oil pressure is 3.9 MPa {40 kg/cm2} or lower.
accumulator pressure 3. Disconnect connector R52 and connect T-adapters to male side.
1 switch (internal short
circuit) Between R52 (male) (1) and (2) Min. 1 Mz
Resistance
Between R52 (male) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and R52, and connect T-adapters to
2 either female side.
(contact with ground
Between ground and MCM1 A (female) (73) or R52
circuit) Resistance (female) (1) Min. 1 Mz
WA470-7 40-923
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
• When the rear brake accumulator oil pressure drops, the brake oil pressure caution lamp
Failure does not light.
• Short circuit or ground fault of rear brake accumulator pressure switch
• If normal, the brake accumulator pressure switch turns OFF when the brake oil pressure
drops.
Related • When the rear brake accumulator oil pressure drops, the brake oil pressure caution lamp
information does not light.
• Input signal (ON/OFF) from the rear brake accumulator pressure switch can be checked
with monitoring function (Code: 04510 "Rear Brake Oil Press").
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective rear brake 2. Make sure that the brake oil pressure is 3.9 MPa {40 kg/cm2} or lower.
accumulator pressure 3. Disconnect connector R54 and connect T-adapters to male side.
1 switch (internal short
circuit) Between R54 (male) (1) and (2) Min. 1 Mz
Resistance
Between R54 (male) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and R54, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and MCM1 A (female) (72) or R54
circuit) Resistance (female) (1) Min. 1 Mz
40-924 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-22 Air cleaner clogging indicator lamp does not light (WA470_7-HP1-400-A-Z0-A)
Failure When the air cleaner is clogged, air cleaner clogging indicator lamp does not light up.
• Ground fault in dust indicator circuit
• When the air cleaner is clogged, its sensor circuit is held to the "CLOSE" (not clogged)
state.
• Voltage at MCM1 A (53) is GND level when air cleaner is normal, and 16 to 24 V when air
General
cleaner is clogged (circuit is open).
information
• Input signal (ON/OFF) from air cleaner clogging sensor can be checked with monitoring
function. (Code: 04509 Air cleaner clogging sensor).
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector E45, and connect T-adapter to male side.
Defective air cleaner 3. Turn starting switch to ON position.
1 clogging sensor
Air cleaner is normal. Max. 1 z
Resistance Between E45 (1) and (2)
Air cleaner is clogged. Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and E45, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and MCM1 A (female) (53) or E45
circuit) Resistance (female) (1) Min. 1 Mz
WA470-7 40-925
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-23 Radiator coolant level caution lamp does not light (WA380_7-HP2-400-A-Z0-A)
When the radiator coolant (or cooling water) is insufficient, the radiator coolant level caution
Failure lamp does not light.
• Short circuit or ground fault of coolant level sensor
• When the radiator coolant (or cooling water) is insufficient, both radiator coolant level
sensor is closed (normal).
Related (The engine may be damaged.)
information • Input signal (ON/OFF) from coolant level sensor can be checked with monitoring function.
(Code: 04509 Engine coolant level sensor)
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R32, and connect T-adapters to each male side.
Defective radiator Radiator coolant level
1 Max. 1 z
coolant level switch Between R32 (male) (1) normal
Resistance and (2)
Radiator coolant level
Min. 1 Mz
low
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A, R32, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and MCM1 A (female) (48) or R32
circuit) Resistance (female) (1) Min. 1 Mz
40-926 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-927
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-928 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-929
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-930 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-26 Fuel level gauge does not indicate correct level (WA470_7-FGB-400-A-Z0-A)
WA470-7 40-931
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-932 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Seat belt caution lamp lights up even when seat belt is fastened, or caution lamp does
Failure not light up when seat belt is not fastened.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Connect T-adapters to connector SBS (male).
3. Check switch itself.
1 Defective seat belt switch When seat belt is
Between SBS (male) fastened Max. 1 z
Resis-
tance (1) and (2) When seat belt is not
Min. 1 Mz
fastened
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 A and SBS, and connect T-adapters
Open circuit in wiring harness to each female side.
2 (wire breakage or defective Between MCM1 A (female) (29) and SBS
Max. 1 z
contact of connector) Resis- (female) (1)
tance Between MCM1 A (female) (13) and SBS
(female) (2) Max. 1 z
WA470-7 40-933
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-934 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-935
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-936 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-937
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-938 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-939
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-31 When starting switch is in ON position, alarm buzzer does not stop
sounding (WA470_7-KB3-400-A-Z0-A)
Failure When starting switch is in ON position, alarm buzzer does not stop sounding.
• If any failure code is displayed, perform troubleshooting for that code first.
• Signal (ON/OFF) to alarm buzzer can be checked with monitoring function.
Related
(Code: 04700 Buzzer)
information
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L20, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Hot short circuit in Under condition that
1 wiring harness alarm buzzer does not Max. 1 V
sound
Voltage Between L20 (1) and (2)
For approx. 1 second
after starting switch is Min. 20 V
turned to ON position
Defective monitor If no failure is found by above checks, monitor controller is defective.
2
controller
40-940 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-32 Kickdown does not work when kickdown switch is turned ON (WA380_7-
F80-400-A-Z0-A)
Failure Kickdown does not work when kickdown switch is turned ON.
• Open circuit or hot short circuit kickdown system
• Input condition (ON/OFF) from the kickdown switch can be checked with monitoring
Related information function
(Code: 02212 Kick Down Switch)
• If failure code [DDW9LD] is displayed, troubleshoot it first.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L14 and connect T-adapter to male side.
Defective kickdown switch Between L14 (male) Kickdown switch: ON Max. 1 z
1
(internal open circuit) Resis- (1) and (2) Kickdown switch: OFF Min. 1 Mz
tance Between ground and each of L14 (male) (1)
and (2) Min. 1 Mz
WA470-7 40-941
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-942 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-33 The hold switch does not work when it is pressed (WA380_7-F90-400-A-Z0-A)
WA470-7 40-943
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-944 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
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 (WA470_7-BHM-400-A-Z0-A)
k Be sure to chock wheels. When performing troubleshooting with parking brake released, be sure
to depress the brake pedal (two persons required for this work).
Parking brake does not work even if it is applied, or the brake drags when parking brake is
Failure released and FR drive is operated.
• Input signal (ON/OFF status) from the neutralizer (parking brake) switch can be checked
with monitoring function (Code: 02215 Parking Brake Switch).
• When 24 V is applied to parking brake solenoid, parking brake is released.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
• Parking brake relay L120 works as self-holding relay.
Related 1. When parking brake switch is operated, pin 5 and pin 6 of parking brake switch are
information connected with each other.
2. Parking brake relay is engaged and L120 works as self-holding relay.
3. When parking brake switch is set to Release position, pin 3 and pin 4 of parking brake
are connected with each other. Since L120 remains engaged, power is supplied to pin
4 of parking brake switch and then flows to L62 (6) pin of transmission controller.
4. If voltage of L62 (6) pin goes to 20 V or above, transmission controller drives parking
brake solenoid from L63 (18) pin (parking brake is released).
• See E-20, failure code [2F00MA].
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse 3 in fuse If fuse is blown, the circuit may be opened or shorted. (See Cause 6.)
1
box 1
1. Turn starting switch to OFF position.
2. Interchange relay L120 with horn relay L119.
Defective parking brake 3. Turn starting switch to ON position.
2 relay (L120) 4. Turn the parking brake switch to the Parking position.
5. Start engine.
• If parking brake indicator lamp lights up, original relay L120 is defective.
• When failure code [D1E6KA], [D1E6KB] or [D1E6KY] is displayed,
perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective auto-idle stop 2. Interchange relay L133 with horn relay L119.
3 parking brake relay 3. Turn starting switch to ON position.
L133 4. Turn the parking brake switch to the Parking position.
5. Start engine.
• If parking brake indicator lamp lights up, original relay L133 is defective.
1. Turn starting switch to OFF position.
Defective parking brake 2. Disconnect connector PB.PS and connect T-adapters to male side.
4
solenoid Between PB.PS (male) (1) and (2) 20 to 60 z
Resistance
Between PB.PS (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector DIODE, and connect T-adapters to diode.
Defective diode DIODE a Check by using multimeter in diode range.
5 (internal open or short No
circuit) Between DIODE (male) (1) (+) and (2) (-)
continuity
Continuity
Between DIODE (male) (2) (+) and (1) (-) Continuity
WA470-7 40-945
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-946 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-947
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-948 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-949
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-950 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-951
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-952 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-953
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-954 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-955
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-39 Flow of loader pump does not increase from the minimum
rate (WA380_7-D51-400-A-Z0-A)
Failure Flow of loader pump does not increase from the minimum rate.
• The loader pump is set to the minimum flow rate due to the hot short in the loader pump
Related EPC solenoid circuit.
information • The current value of loader pump EPC solenoid can be checked with monitoring function.
(Code: 94500 Loader Pump EPC Current)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector R71, and connect T-adapter to female side.
1 wiring harness 3. Turn starting switch to ON position.
Voltage Between R71 (female) (2) and (1) Max. 4.5 V
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L73, and connect T-adapter to female side.
wiring harness
Resistance Between L73 (female) (35) and (23) 5 to 10 z
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-956 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-957
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-958 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-41 None of headlamp, clearance lamp, and tail lamp lights (WA470_7-HQ1-400-A-Z0-
A)
WA470-7 40-959
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-960 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-42 Clearance lamp and tail lamp do not light up or go out (WA470_7-HQ0-400-A-Z0-A)
WA470-7 40-961
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-962 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-963
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-964 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-965
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-966 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-967
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-968 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-969
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-970 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-971
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-972 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-973
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-974 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-975
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-976 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-977
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-48 All of turn signal lamps and hazard lamps do not light up or go
out (WA470_7-HS4-400-A-Z0-A)
Failure All of turn signal lamps and hazard lamps do not light up or go out.
• Defective switch, lamps or wiring harness of turn signal lamps and hazard lamp circuits
• If turn signal lamps and hazard lamps do not go out, remove winker hazard lamp relay 2.
If turn signal lamps and hazard lamps then go out, winker hazard lamp relay 2 is
defective.
• If all turn signal lamps and hazard lamps do not flash, try another flasher unit.
Related • Input condition (ON/OFF) to machine monitor from turn signal lamp and hazard lamp
information switches (right turn signal lamp) can be checked with monitoring function (Code: 04507
Right Turn Signal).
• Input condition (ON/OFF) to machine monitor from turn signal lamp and hazard lamp
switches (left turn signal lamp) can be checked with monitoring function (Code: 04507 Let
Turn Signal).
No. Cause Procedure, measuring location, criteria and remarks
Defective slow-blow If a slow-blow fuse is blown, circuit may have ground fault, etc. (See check on
1 cause 8.)
fuse
1. Turn starting switch to OFF position.
2. Replace winker hazard lamp relay 1 L111 with another relay, for example,
horn relay L119.
Defective winker hazard 3. Turn starting switch to ON position.
2 lamp relay 1 L111 4. Turn ON and OFF hazard lamp switch
5. Operate turn signal lever to right and left
If turn signal lamps become normal, original winker hazard lamp relay 1 L111
is defective.
1. Turn starting switch to OFF position.
2. Replace winker hazard lamp relay 2 L122
Defective winker hazard 3. Turn starting switch to ON position.
3 lamp relay 2 L122 4. Turn ON and OFF hazard lamp switch
5. Operate turn signal lever to right and left
If turn signal lamps become normal, original winker hazard lamp relay 2 L122
is defective.
1. Turn starting switch to OFF position.
Defective turn signal 2. Disconnect connector L04.
4 switch (Internal open or 3. Turn starting switch to ON position.
short circuit) 4. Turn ON and OFF hazard lamp switch
If turn signal lamps become normal, turn signal switch is defective.
1. Turn starting switch to OFF position.
Defective hazard lamp 2. Disconnect connector S_FB.
5 switch (internal open or 3. Turn starting switch to ON position.
short circuit) 4. Operate turn signal lever to right and left
If turn signal lamps become normal, hazard lamp switch is defective.
• Flasher unit power supply
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connector L19 and connect T-adapters to female side.
harness 1 (wire
6 breakage or defective a If check result is unusual, go to check on cause 7.
contact of connector) 3. Turn starting switch to ON position.
Voltage Between L19 (female) (2) and (1) 20 to 30 V
40-978 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-979
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Circuit diagram related to turn signal lamp and winker lamp (hazard lamp)
40-980 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-981
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-982 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Circuit diagram related to turn signal lamp and winker lamp (hazard lamp)
WA470-7 40-983
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-984 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-985
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-986 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-987
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-988 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-989
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-52 Backup lamp does not light up or does not go out (WA470_7-HU1-400-A-Z0-A)
40-990 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-991
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-992 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-993
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-994 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-995
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-996 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-997
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-998 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
WA470-7 40-999
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-1000 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Defective interval wiper a If no failure is found by above checks and the front wiper does not operate
8 timer (internal defect) when the front window washer is activated, the interval wiper timer is
defective.
WA470-7 40-1001
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-1002 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-57 Fuel feed pump does not operate or stop automatically (WA470_7-FHY-400-A-Z0-
A)
WA470-7 40-1003
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
40-1004 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
a Select "Terminal Status" from "KOMTRAX settings" in service menu of machine monitor.
WA470-7 40-1005
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
a Select "GPS & Communication Status" from "KOMTRAX settings" in service menu of machine monitor.
40-1006 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
(Rev. 2011/03)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Failure Failure symptom that appears on machine
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1
2 Probable cause of failure <Contents of description>
(Each number is serial
3 number, not priority • Criteria to determine probable causes
4 sequence.) • Remarks for determination of probable cause
5
WA470-7 40-1007
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1008 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1009
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1010 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting No.
Torque converter relief valve
Slack adjuster
Lockup clutch
Transmission
Brake piston
Brake valve
Failure
Machine starts or gear speed shifts with long time lag. q q q q q q H-6
Machine sways or large shocks are made while machine turns. q H-11
q q q q H-14
Brake
WA470-7 40-1011
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting No.
Torque converter relief valve
Slack adjuster
Lockup clutch
Transmission
Brake piston
Brake valve
Failure
q H-30
significantly or engine to stall.
hydraulic component
Large shocks are made when work equipment starts to move and
q H-31
stops.
When single work equipment is relieved hydraulically, other work
q H-32
equipment moves.
E.C.S.S. (travel damper) does not work and machine pitches and
H-33
bounces.
Bucket does not stop at the position which is set with remote bucket
H-34
positioner
Fan system
Fan speed is abnormal (too high or low, or fan does not rotate). q H-35
40-1012 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting No.
Flow control valve
Brake accumulator
Steering cylinder
Steering pump
Parking brake
Stop valve
Orbitrol
Failure
Machine starts or gear speed shifts with long time lag. q H-6
Machine sways or large shocks are made while machine turns. q q q q q q q q H-11
q H-14
Brake
WA470-7 40-1013
Fan
system
Failure
mode)
40-1014
40 Troubleshooting
Parking brake
Troubleshooting of hydraulic and mechanical system (H-
Brake accumulator
Steering pump
Orbitrol
Steering cylinder
Stop valve
Troubleshooting No.
H-36
H-35
WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting No.
Bucket control valve (spool)
Boom control valve (spool)
Transmission controller
Hydraulic tank strainer
PT-
O
Machine does not move off. q q H-1
Machine starts or gear speed shifts with long time lag. q q q H-6
Machine sways or large shocks are made while machine turns. H-11
H-14
Brake
q q q H-35
Fan
WA470-7 40-1015
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Pilot circuit (between EPC valve and work equipment control valve)
Shut off valve (for pilot circuit of work equipment valve)
Troubleshooting No.
Boom control lever
Bucket EPC valve
Boom EPC valve
Bucket cylinder
Lift cylinder
Failure
Machine starts or gear speed shifts with long time lag. H-6
Machine sways or large shocks are made while machine turns. H-11
H-14
Brake
Lift cylinders do not serve to hold bucket on ground (bucket rises off
hydraulic component
q q q H-20
ground).
Hydraulic drift of boom is large. q H-21
40-1016 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Pilot circuit (between EPC valve and work equipment control valve)
Shut off valve (for pilot circuit of work equipment valve)
Troubleshooting No.
Boom control lever
Bucket EPC valve
Boom EPC valve
Bucket cylinder
Failure Lift cylinder
Boom and bucket control levers do not move smoothly and heavy to
q q q q H-29
hydraulic component
move.
Operating work equipment causes engine speed to lower
q q q q H-30
significantly or engine to stall.
Large shocks are made when work equipment starts to move and
q q q q q H-31
stops.
When single work equipment is relieved hydraulically, other work
q H-32
equipment moves.
E.C.S.S. (travel damper) does not work and machine pitches and
q q q q H-33
bounces.
Bucket does not stop at the position which is set with remote bucket
H-34
positioner
Fan speed is abnormal (too high or low, or fan does not rotate).
system
q q H-35
Fan
WA470-7 40-1017
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1018 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1019
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1020 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Table 1
Clutches to be used
F R 1st 2nd 3rd 4th
In auto shift
q
mode
N
In manual
q q q q
shift mode
F1 q q
Gear speed
F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
• When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.
WA470-7 40-1021
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1022 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1023
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low,
or gear speed does not shift (WA470_7-D20-400-A-Z0-A)
Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not
Failure
shift.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
Related 15SGLH, 15SHL1, or 15SHLH).
information • Check that wheel brake or parking brake is not dragged.
• Torque converter oil pressure can be checked with monitoring function. (Monitoring code:
32601 (Input pressure), 32603 (Output pressure))
No. Cause Procedure, measuring location, criteria and remarks
Defective strainer of
1 transmission charge Check strainer for clogging.
pump
Air sucked in on suction
2 side of transmission Check suction piping for cracks, etc.
charge pump
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and 2,000 rpm.
2.32 ± 0.2 MPa
Defective main relief Low idle
3 valve of transmission {23.5 ± 2 kg/cm2}
Main relief pressure Engine speed
charge pump 2.55 ± 0.2 MPa
2,000 rpm
{26 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (fatigue of spring) and internal defect (defective valve seat).
Clogged last chance If no failure is found by check on cause (3) but lockup clutch pressure is low or
4 "0", check last chance filter for clogging.
filter
a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Torque converter 0.1 to 0.88 MPa
input pressure Brake OFF
Improper torque {1.0 to 9.0 kg/cm2}
5 converter pressure Torque converter 0.06 to 0.71 MPa
(relief valve) output pressure Brake OFF
{0.6 to 7.1 kg/cm2}
When pressure cannot be adjusted to normal level, check relief valve for
malfunction (fatigue of spring) and internal defect (defective valve seat).
• If torque converter output pressure is below standard value, oil cooler may
be broken.
a Be ready with engine stopped, then perform troubleshooting during torque
converter stall operation.
Defective torque Economy mode
6 ON 1,710 ± 100 rpm
converter Torque converter switch
stall speed Power mode 1,785 ± 100 rpm
ON
switch
40-1024 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
WA470-7 40-1025
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
• When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.
40-1026 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-5 Large shock is made when machine starts or gear is shifted (WA470_7-C10-
400-A-Z0-A)
WA470-7 40-1027
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
• When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.
40-1028 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-6 Machine starts or gear speed shifts with long time lag (WA470_7-C60-400-A-Z0-A)
Failure Machine starts or gear speed shifts with long time lag.
• Check that transmission oil level is normal.
• If any failure code is displayed, perform trouble shooting for that failure code first.
Related 15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
information 15SGLH, 15SHL1, 15SHLH, DGF1KA, or DGF1KB)
• Check that drive shaft, etc. are normal.
• Engine speed can be checked with monitoring function. (Monitoring code: 01001)
No. Cause Procedure, measuring location, criteria and remarks
Defective strainer of
If unusual noise is heard from charge pump or transmission oil filter when
1 transmission charge
transmission oil temperature is low, check strainer for clogging.
pump
Air sucked in on suction
2 side of transmission Check suction piping for cracks, etc.
charge pump
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and 2,000 rpm.
2.32 ± 0.2 MPa
Defective main relief Low idle
3 valve of transmission {23.5 ± 2 kg/cm2}
Main relief pressure Engine speed
charge pump 2.55 ± 0.2 MPa
2,000 rpm
{26 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (setting of spring) and internal defect (defective valve seat).
Clogged last chance If no failure is found by check on cause (3) but lockup clutch pressure is low or
4 “0“, check last chance filter for clogging.
filter
a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Output pressure of F 2.06 ± 0.15 MPa
F1
clutch ECMV {21 ± 1.5 kg/cm2}
Output pressure of R 2.06 ± 0.15 MPa
R1
clutch ECMV {21 ± 1.5 kg/cm2}
WA470-7 40-1029
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
40-1030 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1031
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
• When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.
40-1032 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1033
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1034 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1035
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1036 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1037
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1038 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1039
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-12 Turning radius differs between right and left turns (WA380_7-L90-400-A-Z0-A)
a For adjustment procedure of stopper bolt, see k Take care not to loosen stopper bolt
Testing and adjusting, "Testing and adjusting (1) excessively so that it does not
stopper bolt". press spool.
(Reference) Adjustment procedure of stopper
bolt for stop valve
40-1040 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1041
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)
40-1042 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1043
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1044 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1045
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1046 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1047
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1048 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1049
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1050 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Failure Lift cylinders do not serve to hold bucket on ground (bucket rises off ground).
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DB90KK, DB92KK, DB95KX, DK59L8, DW4PKY, DW4QKA, DW4QKB, DW4QKY,
DW4RKY, DW4SKY, DWM1KY, DXA1KY, DXHJKY, or DXHKKY)
• If failure symptom of "Boom moves slow" or "Boom lacks lifting power" also appears,
Related perform troubleshooting for "H-18" as well.
information • Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
• Boom control lever stroke can be checked with monitoring function. (Monitoring code:
42104)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
1 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure of pilot
pressure for boom control valve (RAISE and LOWER).
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
34.3 (+1.8/-4.4) MPa
Boom LOWER
Defective suction-safety Relief pressure Lift cylinder {350 (+18/-45) kg/
2 hydraulic relief
valve cm2}
If only boom LOWER relief pressure is low, suction safety valve may
malfunction.
Replace suction safety valve assembly.
Stroke to
Lever strike of boom Boom control LOWER
Defective boom control control lever Min. -74%
3 lever position
lever
a Stroke means lever travel to point just before detent position.
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of boom high idle.*
4
LOWER EPC valve Output pressure of Boom control 1.91 ± 0.15 MPa
LOWER
EPC valve lever {19.5 ± 1.5 kg/cm2}
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
5 Defective lift cylinder If measured relief pressure is below standard value, disconnect hydraulic
hose from lift cylinder head end, and relieve lift cylinder hydraulically at its
stroke end. If oil flows out of cylinder, cylinder piston ring is defective.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)
WA470-7 40-1051
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1052 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Boom moves up and down during operation. (When machine is performing digging or leveling
Failure work with boom control lever set in "HOLD" position, bucket and boom move up and down
along ground.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DK59KA, DK59KY, DK59L8, DW4PKY, or DW4QKY)
Related • Work equipment pump pressure can be checked with monitoring function. (Monitoring
information code: 94700)
• Check hydraulic drift of boom, and check that machine body is raised off ground by using
lift cylinders. If any failure is found, see troubleshooting for H-20 and H-21 respectively.
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
34.3 (+1.8/-4.4) MPa
Boom LOWER
Relief pressure Lift cylinder {350 (+18/-45) kg/
hydraulic relief
Defective suction safety cm2}
1 valve at lift cylinder If only boom LOWER relief pressure is low, suction safety valve may
head side malfunction.
Move boom several times to allow lift cylinders to move over their whole
strokes. After that, if machine body is raised off ground by using lift cylinders,
cause of this failure is vacuum generated in cylinder. If this symptom occurs
repeatedly, valve seat of suction valve may be defective.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
2 Defective lift cylinder If measured relief pressure is below standard value in check on cause (1),
disconnect hydraulic hose from lift cylinder head end, and relieve lift cylinder
hydraulically at its stroke end. If oil flows out of cylinder, cylinder piston ring is
defective.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)
WA470-7 40-1053
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1054 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1055
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1056 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1057
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1058 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1059
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1060 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-28 Bucket tilts back and forth during carrying load (work equipment
valve in HOLD) (WA470_7-M90-400-A-Z0-A)
Failure Bucket tilts back and forth during carrying load (work equipment valve in HOLD).
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DK5BKA, DK5BKY, DK5BL8, DW4RKY, or DW4SKY)
Related • Check pins and bushings of work equipment linkage for "play" (unusual noise).
information • Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle. (For measuring procedure, see Testing and adjusting, "Testing
work equipment oil pressure".)
Malfunction of suction 34.3 (+1.8/-4.4) MPa
safety valve in bucket Relief pressure Bucket cylinder Bucket DUMP
1 relief {350 (+18/-45) kg/
cylinder circuit on head cm2}
side.
If only relief pressure on bucket DUMP side is below standard value, suction
safety valve on bucket DUMP circuit may malfunction.
Replace valve assembly because valve cannot be adjusted when it is
installed to machine.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective bucket If measured relief pressure is below standard value in check on cause (1),
2 cylinder disconnect hydraulic hose from bucket cylinder head end, and relieve bucket
cylinder hydraulically at its stroke end. If oil flows out of cylinder, cylinder
piston ring is defective.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)
WA470-7 40-1061
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-29 Boom and bucket control levers do not move smoothly and are
heavy to move (WA470_7-LS1-400-A-Z1-A)
Failure Boom and bucket control levers do not move smoothly and are heavy to move.
Related
information
No. Cause Procedure, measuring location, criteria and remarks
When lever
From HOLD to moves (to short Max. 17.1 N {1.8
RAISE of detent kgf}
position)
When lever 4.9 to 30.5 N
From RAISE to passes through
HOLD detent position (0.5 to 3.1 kgf)
When lever
Defective boom control
1 Lever control effort From HOLD to moves (to short Max. 17.1 N {1.8
lever of detent kgf}
LOWER
position)
When lever
From LOWER passes through Max. 30.3 N {3.1
to FLOAT kgf}
detent position
When lever 4.9 to 30.5 N
From FLOAT to passes through
HOLD detent position (0.5 to 3.1 kgf)
From HOLD to When lever Max. 26.6 N {2.7
DUMP moves kgf}
When lever
From HOLD to moves (to short Max. 17.1 N {1.8
Defective bucket control of detent kgf}
2 Lever control effort TILT
lever position)
When lever 4.9 to 30.5 N
From TILT to passes through
HOLD detent position (0.5 to 3.1 kgf)
40-1062 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
WA470-7 40-1063
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-31 Large shocks are made when work equipment starts to move and
stops (WA470_7-FT3-400-A-Z0-A)
Failure Large shocks are made when work equipment starts to move and stops.
• Boom control lever stroke (expressed in percentage) can be checked with monitoring
function. (Monitoring code: 42104)
• Input signal (voltage) from boom lever potentiometer (main) can be checked with
Related monitoring function. (Monitoring code: 42000)
information • Input signal (voltage) from bucket lever potentiometer (main) can be checked with
monitoring function. (Monitoring code: 42002)
• Bucket control lever stroke (expressed in percentage) can be checked with monitoring
function. (Monitoring code: 42106)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
1 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure of pilot
pressure for work equipment control valve (boom and bucket).
• Pilot circuit between EPC valve and work equipment control valve may be
2 Clogged pilot circuit clogged with dirt, etc.
Check pilot circuit of work equipment that causes large shock.
Malfunction of main • If abnormally large shock is made, main spool may not move smoothly.
3 spool of control valve After releasing remaining pressure, check main spool for jerky motion.
Boom control RAISE 44.5 ± 4.4 mm
Control lever stroke
Boom control lever LOWER Min. 31.2 mm
4
Defective lever Check that lever is not caught or it does not become heavy to move while
operating it.
Be ready with starting switch at OFF position, and then turn starting switch to
ON position to perform troubleshooting.
Lever in
2.4 to 2.6 V
NEUTRAL
RAISE
(just before the 3.38 to 4.04 V
Boom lever detent position)
5
Defective potentiometer Voltage from Boom control RAISE
potentiometer lever 3.90 to 4.40 V
(Detent position)
LOWER
(just before the 0.96 to 1.62 V
detent position)
FLOAT 0.6 to 1.10 V
Bucket control DUMP 44.5 ± 4.4 mm
Control lever stroke
Bucket control lever Tilt control 44.5 ± 4.4 mm
6
Defective lever Check that lever is not caught or it does not become heavy to move while
operating it.
Be ready with starting switch at OFF position, and then turn starting switch to
ON position to perform troubleshooting.
Lever in
2.4 to 2.6 V
NEUTRAL
Bucket lever Tilt control
7 (just before the 3.38 to 4.04 V
Defective potentiometer Voltage from Bucket control
potentiometer lever detent position)
Tilt control
3.90 to 4.40 V
(Detent position)
Full DUMP 0.60 to 1.10 V
40-1064 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
For boom RAISE a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
8 Malfunction of EPC
Output pressure of Boom control 2.94 ± 0.16 MPa
valve RAISE
EPC valve lever {30.0 ± 1.6 kg/cm2}
For boom LOWER a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
9 Malfunction of EPC
Output pressure of Boom control 1.99 ± 0.14 MPa
valve LOWER
EPC valve lever {20.3 ± 1.4 kg/cm2}
For bucket TILT a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
10 Malfunction of EPC
Output pressure of Bucket control 3.1 ± 0.17 MPa
valve TILT
EPC valve lever {31.5 ± 1.7 kg/cm2}
For bucket DUMP a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
11 Malfunction of EPC
Output pressure of Bucket control 2.75 ± 0.14 MPa
valve DUMP
EPC valve lever {28 ± 1.4 kg/cm2}
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)
WA470-7 40-1065
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1066 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-33 E.C.S.S. (travel damper) does not work and machine pitches and
bounces (WA470_7-CG1-400-A-Z0-A)
Failure E.C.S.S. (travel damper) does not work and machine pitches and bounces.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(D192KA, D192KB, D192KY, DLT3KA, or DLT3LC)
Related • Transmission output shaft speed can be checked with monitoring function. (Monitoring
information code: 31400)
• Output command value (ON/OFF) to travel damper solenoid can be checked with
monitoring function. (Monitoring code: 03705)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
low idle.
Defective ECSS Approx. 12.3 MPa
1 accumulator charge Charge relief Boom control RAISE (*) {Approx. 125 kg/
relief valve pressure lever
cm2}
(*) While raising boom slowly with engine running at low speed, measure
stabled charge pressure.
If no failure is found by check on cause (1) and travel damper does not work
Defective ECSS (travel at all, travel damper solenoid valve may be defective.
2 damper) solenoid valve
Check solenoid valve spool for seizure and locking.
Defective ECSS If no failure is found by checks on causes (1) and (2), and travel damper does
3 accumulator selector not work at all, ECSS accumulator selector valve may be defective.
valve Check selector valve spool for seizure and locking.
a Be ready with engine stopped, then perform troubleshooting with engine
stopped.
Approx. 2.94 MPa
Nitrogen gas charged pressure {Approx. 30.0 kg/
Defective ECSS
4 cm2}
accumulator
If nitrogen gas charged pressure drops immediately, sealing of accumulator
may be defective.
Nitrogen gas charged pressure varies depending on outside air temperature.
Check charged pressure by referring to Testing and adjusting section.
While displaying monitoring screen of transmission output shaft speed on
Defective transmission machine monitor, drive machine on flat road at F1 or F2 gear speed with
5 output shaft speed engine at low speed. Increase engine speed gradually and check that
sensor transmission output shaft speed indicated on monitoring screen increases as
engine speed increases (travel speed shall be 5 km/h and above).
Defective transmission If no failure is found by checks on causes (1) to (5), transmission controller
6 may be defective.
controller
WA470-7 40-1067
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-34 Bucket does not stop at the position which is set with remote
bucket positioner (WA470_7-M91-400-A-Z0-A)
Failure Bucket does not stop at the position which is set with remote bucket positioner
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related (DKA1KA, DKA1KY, DKA0KA, DKA0KY, or DKA0L0)
information • Check pins and bushings of work equipment linkage for "play" (unusual noise).
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine
stopped.
Lower the work equipment to the
ground, remove sensor cover (1)
Total clearance of and (2), bolt (3), and washer (4),
Defective ECSS (a) and (b) Max. 1.5 mm
and measure the clearance
1 accumulator charge between lock boss (5) and the
relief valve hole.
Rotation lock may be worn by friction if clearances (a) and (b) of rotation lock
of bell crank pin are large. (As a result, bucket angle sensor becomes
inaccurate)
Perform repair of the actual machine according to 50. Disassembly and
assembly, "Repair of bell crank pin rotation lock".
40-1068 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
H-35 Fan speed is abnormal (too high or low, or fan does not
rotate) (WA470_7-FTP-400-A-Z0-A)
Failure Fan speed is abnormal (too high or low, or fan does not rotate).
• When engine is started for first time after hydraulic oil replacement, fan may temporarily
rotates at higher speed but this is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related (DW7BKA, DW7BKB, DW7BKY, DLM3KA, DLM3LC, LA00L3, DX16KA, DX16KB,
information DB16KY, DGT1KA, DGT1KB, or DGH2KX)
• Engine speed can be checked with monitoring function. (Monitoring code: 01001)
• Radiator fan speed can be checked with monitoring function. (Monitoring code: 10009)
No. Cause Procedure, measuring location, criteria and remarks
a For measuring procedure, see "Testing engine speed" in "Testing and
adjusting".
1 Defective engine speed Engine low idle 825 ± 25 rpm
Engine speed
Engine high idle 2,170 ± 50 rpm
If engine speed is not increased to specification, perform troubleshooting for
"S-5 Engine runs rough or is unstable".
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
2 Defective fan speed Torque converter oil temperature:
Fan speed Min. 105°C 1,300 ± 200 rpm
Hydraulic oil temperature: Min.
95°C
Defective PTO (fan
3 Fan pump drive of PTO may be defective.
pump drive)
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of
high idle.*
4 accumulator charge
valve (relief valve) Fan motor drive Fan adjustment mode: 100% 14.3 ± 2.1 MPa
pressure Hydraulic oil temperature: 50°C {146 ± 22 kg/cm2}
If pressure does not reach specified value after relief valve is adjusted in
5 Defective fan pump check on cause (4), fan pump may have internal defect.
Check strainer of self-pressure reducing valve inlet for metal particles.
a Be ready with engine stopped, then perform troubleshooting with engine at
full speed and fan in reverse rotation mode.
Fan reverse Fan adjustment mode: 100% 1.98 to 3.04 MPa
solenoid output
Malfunction of fan motor pressure Hydraulic oil temperature: 50°C {20.2 to 31.0 kg/cm2}
6 (direction selector
valve) a Release remaining pressure from hydraulic tank and piping, and then
perform troubleshooting with engine stopped.
• Check direction selector valve spool in valve body for seizure or sticking.
(Spool shall move smoothly and shall not be caught.)
• Take direction selector spool from valve body, and check it for defects and
dirt.
If no failure is found by checks on causes (1) to (6), fan motor may have
7 Defective fan motor
internal defect.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)
WA470-7 40-1069
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
40-1070 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on engine
Related Information related to the detected failure or troubleshooting
information
Probable cause Contents of check and remarks Remedy
1 <Contents of description>
2 Probable causes for
trouble (Each number is • Contents of check to judge • Actions to eliminate probable
3 serial number, not priority probable causes causes of trouble
4 sequence.) • Remarks required for
5 judgment
WA470-7 40-1071
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1072 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
S-2 The engine cranks but exhaust smoke does not come out (PC400-A27-400-A-Z0-
A)
Failure The engine cranks but exhaust smoke does not come out
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When fuel tank is inspected, it is found to
1 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
3 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
7 Defective common rail Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
8 Defective supply pump when checking common rail pressure on Replace supply pump
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with
monitoring function. (Code: 36400 (MPa))
• When priming pump is operated, no
9 Defective priming pump Replace priming pump
resistance is felt or it is heavy
Clogging of feed pump gauze • Gauze filter is clogged Clean or replace
10 gauze filter
filter
• Common rail pressure does not go down Loosen injection piping
when when pressure is checked with and high pressure
Improper bleeding of common
11 rail or injection piping monitoring function and then stopped piping mounting nuts
(Code: 36400 Common rail pressure) on common rail and
(pressure will not decrease if air is present) bleed air
WA470-7 40-1073
40 Troubleshooting
Troubleshooting of engine (S-mode)
S-3 Fuel is injected but engine does not start (incomplete combustion,
engine seems to start but does not) (PC400-A28-400-A-Z0-A)
Fuel is injected but engine does not start (incomplete combustion, engine seems to start
Failure but does not)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• Specific gravity of electrolyte and voltage of Add electrolyte or
1 Defective battery
battery are low charge battery
• When fuel tank is inspected, it is found to
2 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
3 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
4 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
5
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
6 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
7 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
• When priming pump is operated, no
8 Defective priming pump Replace priming pump
resistance is felt or it is heavy
Clogging of feed pump gauze Clean or replace
9 • Gauze filter is clogged
filter gauze filter
• Air cleaner dust indicator is at a caution Test and adjust air
10 Clogged air cleaner element
level cleaner element
• During pre-heating operation, intake air
heater mount is cold
• When engine is preheated or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor heater
does not indicate properly
• Check valve clearance
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve Replace valve or
12 Worn valves or rocker arms clearance") rocker arm
• While engine is running, unusual noise is
heard around cylinder head
• Testing compression pressure
Replace piston ring or
13 Defective piston ring (Reference: See Testing and adjusting,
piston
"Testing compression pressure")
Defective injector • When a certain cylinder is cut out, engine
speed does not change
14 (clogged injector, defective Replace Injector
(Note: see "Handling cylinder cutout mode
injection) operation" section of Testing and adjusting)
• Since this is an internal defect, Replace engine
15 Defective engine controller troubleshooting cannot be performed. controller.
40-1074 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
6
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
7 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
8 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
9 Defective common rail Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
when checking common rail pressure on Replace supply pump
10 Defective supply pump
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with
monitoring function. (Code: 36400 (MPa))
Clogging of feed pump gauze Clean or replace
11 • Gauze filter is clogged
filter gauze filter
• Air cleaner dust indicator is at a caution Check, clean air
12 Clogged air cleaner element
level cleaner element
• During pre-heating operation, intake air
heater mount is cold
• When engine is preheated or when Replace intake air
13 Defective intake air heater
temperature is low, preheating monitor heater
does not indicate properly
WA470-7 40-1075
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1076 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
7 Defective common rail Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
Defective supply pump when checking common rail pressure on Replace supply pump
8
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with
monitoring function. (Code: 36400 (MPa))
Clogging of feed pump gauze Clean or replace
9 • Gauze filter is clogged
filter gauze filter
• If Crankcase Pressure High Error (failure
code: CA555) is still displayed after KCCV
Abnormally high crankcase filter element is replaced, blow-by pressure Perform
10 pressure may be high due to seizure or damage of troubleshooting for
KVGT (see Testing and adjusting, "Testing cause 10 and after.
blow-by pressure")
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
11 Defective injector • When a certain cylinder is cut out, engine Replace injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
• Unusual noise is heard from KVGT
• Check if KVGT shaft rotates
12 Seized or broken KVGT Replace KVGT
(Move KVGT vanes with hand in axial and
radial directions to judge)
• When engine is cranked, Unusual noise is
13 Incorrect valve clearance generated around cylinder head Adjust valve clearance
• Check valve clearance
WA470-7 40-1077
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1078 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Performing air
is performed, air comes out bleeding operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
• When priming pump is operated, no
7 Defective priming pump Replace priming pump
resistance is felt or it is heavy
Clogging of feed pump gauze Clean or replace
8 • Gauze filter is clogged
filter gauze filter
• See Testing and adjusting, "Checking fuel Replace supply pump
9 Defective supply pump
delivery, return rate and leakage" and pressure limiter
Defective air intake hose
• Visually check the air intake hose for Replace air intake
10 (from air cleaner to KVGT damage hose
inlet)
• Check the intake manifold for internal Replace air intake
11 Defective air intake manifold damage manifold
Defective boost piping and
connections Correct or replace
12 • Air flows out from boost piping
(from KVGT outlet to air intake boost piping
manifold)
Defective exhaust pipes • Check exhaust pipes for damage and
exhaust gas leakage
13 (from exhaust manifold to Replace exhaust pipes
(Check heat insulation cover and soot on
KDPF inlet) heat shield plate)
• Check valves and rocker arms
Replace valve or
14 Damaged valve or rocker arm (Unusual noise is heard and engine
stopped suddenly) rocker arm
• Metallic powders are found in oil drained
from oil pan
• Remove oil pan and check pistons and
Broken or seized piston or Replace piston or
15 connecting rod connecting rods
connecting rod
(Reference: Unusual noise is heard and
engine stopped suddenly, or stopped after
overheating)
• Metallic powders are found in oil drained
Broken or seized crankshaft from oil pan Replace crankshaft
16 main bearing • Remove oil pan and check crankshaft main main bearing
bearing
• Check engine controller power supply
Correct engine
Defective engine controller wiring
17 power supply wiring controller power
(Reference: See Troubleshooting, Failure
supply wiring
Code [CA343].)
WA470-7 40-1079
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1080 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
• Check for leaks from boost system (KVGT Correct or replace
7 Leakage in boost system outlet to aftercooler, aftercooler to air intake parts around boost
manifold) piping
Clogging of feed pump gauze Clean or replace
8 • Gauze filter is clogged
filter gauze filter
• Replace sensor and check if problem is
Defective mass air flow and corrected Replace mass air flow
9 temperature sensor (Failure code may not be issued if the and temperature
sensor is covered with dust.) sensor
WA470-7 40-1081
40 Troubleshooting
Troubleshooting of engine (S-mode)
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Check fuel circuit for leaking")
• See Testing and adjusting, "Checking fuel Replace supply pump
7 Defective supply pump
delivery, return rate and leakage" and pressure limiter
Clogging of feed pump gauze Clean or replace
8 • Gauze filter is clogged
filter gauze filter
Clogged air cleaner element Check, clean air
9 • Air cleaner dust indicator in caution level
cleaner element
• Check air cleaner and airflow screen for Correct or replace air
10 Defective air cleaner
deformation cleaner
Defective air intake hose
• Visually check the air intake hose for Replace air intake
11 (from air cleaner to KVGT damage hose
inlet)
• Check the intake manifold for internal Replace air intake
12 Defective air intake manifold damage manifold
Defective boost piping and
connections Correct or replace
13 • Air flows out from boost piping
(from KVGT outlet to air intake boost piping
manifold)
Improperly installed boost • Air leaks from boost pressure sensor Correct mounting of
14 pressure sensor mounting boost pressure sensor
Defective exhaust pipes • Check exhaust pipes for damage and
exhaust gas leakage
15 (from exhaust manifold to Replace exhaust pipes
(Check heat insulation cover and soot on
KDPF inlet) heat shield plate)
16 Gas leakage from EGR piping • Gas leaks from EGR piping Replace EGR piping
Check intake and exhaust
system • Measure boost pressure
Correct or replace
17 (KVGT outlet to air intake (Reference: See Testing and adjusting,
defective parts
manifold, exhaust manifold to "Testing boost pressure")
KDPF inlet)
• Unusual noise is heard from KVGT
• Check if KVGT shaft rotates
18 Seized or broken KVGT Replace KVGT
(Move KVGT vanes with hand in axial and
radial directions to judge)
40-1082 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
WA470-7 40-1083
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1084 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
WA470-7 40-1085
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1086 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
WA470-7 40-1087
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1088 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) (PC400-
B40-400-A-Z0-A)
Failure Oil is in coolant (or coolant spurts or coolant level goes down)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Perform
troubleshooting for "S-
1 Milky engine oil • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)".
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block
WA470-7 40-1089
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1090 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
Failure Fuel mixes into engine oil (smells of diluted diesel fuel)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
1 Defective injector • When a certain cylinder is cut out, engine Replace Injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
Fuel leakage from injector or
2 • Check injector or O-ring Replace injector O-ring
O-ring (spill circuit)
Defective seal between
• Check seal between injector and injection
3 injector and injection piping, Repair or replace
piping, and check injection piping for cracks
cracks in injection piping
• Confirm that fuel no longer mixes into oil
4 Defects in supply pump Replace supply pump
after supply pump is replaced
WA470-7 40-1091
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1092 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
WA470-7 40-1093
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1094 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
WA470-7 40-1095
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1096 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
WA470-7 40-1097
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1098 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)
WA470-7 40-1099
40 Troubleshooting
Troubleshooting of engine (S-mode)
40-1100 WA470-7
SHOP MANUAL
WHEEL LOADER
WA470-7
Model Serial Number
WA470-7 50-1
50 Disassembly and assembly
Table of contents
50-2 WA470-7
50 Disassembly and assembly
Table of contents
WA470-7 50-3
50 Disassembly and assembly
General information on disassembly and assembly
Removal and installation of TTTT assembly • Common tools that are necessary for installation
Special tools are described as [1], [2] ... etc. and their part
• Special tools which are necessary for removal or numbers, part names and quantities are not
installation of assemblies are described as described.
A1•••X1 etc. and their part numbers, part names, • Marks shown in the installation section are
necessities, and quantities are described in the explained below.
special tool list. k: This mark indicates safety-related
• Marks used in the column of necessity are precautions which must be followed when
explained below. performing the work.
t: Tools are not substituted, must always be
equipped (used). a : This marks gives guidance or precautions
q: Tools extremely useful if available or tools when performing the work.
that can be substituted with commercially
available tool. 4 : This mark shows the weight of a part or
• For details and the sketches of the special tools, the assembled parts for a device.
see "special tool list" and "sketches of special
tools". 2 : This mark indicates a specific coating
Removal agent to be used.
• In the removal section, the work procedures, 3 : This mark indicates the specified
precautions and know-how to do the work and tightening torque.
the amount of oil and coolant to be drained are
described. 5 : This mark indicates the amount of oil or
• Common tools that are necessary for the coolant to be added.
removal work are indicated as [1], [2] ... etc. and
their part numbers, part names and quantities Disassembly and assembly of TTTT assembly
are not described. Special tools
• Marks used in the removal section are explained • Special tools which are necessary for
below. disassembly and assembly of assemblies are
described as A1•••X1 etc. and their part
k: This mark indicates safety-related numbers, part names, necessities, and
precautions which must be followed when quantities are described in the special tool list.
performing the work. • Marks used in the column of necessity are
explained below.
a : This mark gives guidance or precautions when t: Tools are not substituted, must always be
performing the work. equipped (used).
[*1]: This mark indicates that instructions or q: Tools extremely useful if available or tools
precautions for the assembly installation work are that can be substituted with commercially
given in the installation section. available tool.
• For details and the sketches of the special tools,
6 : This mark shows the amount of oil or see "special tool list" and "sketches of special
coolant to be drained. tools".
Disassembly
4 : This mark shows the weight of a part or • In the disassembly section, the work
the assembled parts for a device. procedures, precautions and know-how to do
Installation the work, and the amount of oil and coolant to be
• Unless otherwise instructed the installation of drained are described.
assemblies is to be made in the reverse order to • Common tools that are necessary for the
removal. disassembly work are indicated as [1], [2] ... etc.
• Instructions and precautions for assembly and their part numbers, part names, and
installation are shown with [*1] mark in the quantities are not described.
removal section, identifying which step the • Marks used in the disassembly section are
instructions are intended for. explained below.
50-4 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
WA470-7 50-5
50 Disassembly and assembly
General information on disassembly and assembly
a The recommended coating materials such as adhesives, gasket sealants, and greases used for
disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming
out.
• Use for plastic (except polyethylene,
20g polypropylene, tetrafluoroethylene, and
Polyethylene vinyl chloride), rubber, metal, and non-
LT-1B 790-129-9050 (2 pcs. container metal parts which require immediate
contained)
and strong adhesion.
• Features: Resistance to heat and
50 g Polyethylene chemicals
LT-2 790-129-9180
container • Use to fix and seal bolts and plugs.
Adhesive:
790-129-9060 1 kg • Use to bond and seal metal, glass and
LT-3 (Set of adhesive Can
Hardener: plastics.
and hardener)
500 g
250 g Polyethylene • Use to seal plugs for blank holes.
LT-4 790-129-9040
container
• Heat-resistant seal used to repair
Holtz MH705 790-129-9120 75 g Tube engines
• Instantaneous adhesive
50 g Polyethylene • Curing time: From 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 • Use mainly to bond metals, rubbers,
container
plastics, and woods.
• Instantaneous adhesive
• Quick-curing type (max. strength is
Aron Alpha 201 2g Polyethylene
790-129-9130 obtained after 30 minutes)
container
• Use mainly to bond rubbers, plastics,
and metals.
• General-purpose instantaneous
adhesive with excellent resistance to
Loctite 499 428-99-80070 20 g Tube heat and impact
• Use on the bushing mounting faces of
axle supports.
• Features: Resistance to heat and
Polyethylene chemicals
Loctite 648-50 79A-129-9110 50 cc • Use for fitted portions used at high
container
temperatures.
50-6 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Liquid gasket
Komatsu code Part No. Capacity Container Main features and applications
• Use to seal various thread portions,
Polyethylene pipe joints, and flanges.
LG-5 790-129-9080 1 kg
container • Use to seal taper plugs, elbows, and
nipples for hydraulic piping.
• Features: Silicon-based heat and
cold-resistant sealant
200 g • Use to seal thread portions and flange
LG-6 790-129-9160 Tube
surface.
• Use to seal oil pan, final drive case,
etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based, heat and
cold-resistant, vibration-resistant,
ThreeBond 419-15-18131 100 g Tube impact-resistant sealant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the
LG-9 circle gear top seal which is not
ThreeBond 790-129-9310 200 g Tube clamped by bolts, gaps in the weld
1206D which must be caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when the
ThreeBond 790-129-9320 200 g Tube radiator hoses are put on.
1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11 solid gaskets.
790-129-9330 200 g Tube
ThreeBond 1121 • Use for covers of the transmission
case and steering case etc.
ThreeBond 1211 790-129-9090 100 g Tube • Liquid gasket used to repair engine
WA470-7 50-7
50 Disassembly and assembly
General information on disassembly and assembly
Grease
Komatsu code Part No. Capacity Container Main features and applications
SYG2-400LI-A
G2-LI SYG2-16LI • Lithium grease with extreme pressure
G0-LI (*) SYGA-16CNLI Various Various lubrication performance, general
*: For cold regions SYG0-400LI-A(*) purpose type
SYG0-16CNLI(*)
• Use for parts under heavy load.
Caution:
• Do not use this grease for rolling
Molybdenum SYG2-400M 400 g x 10 Bellows-type bearings like swing circle bearings,
disulfide grease SYG2-400M-A 400 g x 20 container etc. and splines.
LM-G (G2-M) SYGA-16CNM 16 kg Can • Use this grease for work
equipment pins only when
installing them, but do not use it
afterward.
Hyper White
SYG2-400T • Higher seizure resistant, heat
Grease Bellows-type
SYG2-16CNT 400 g resistant and water resistant than
G2-T container molybdenum disulfide grease.
SYG0-400T(*) 16 kg • Not conspicuous on machine since
G0-T (*) Can
SYG0-16CNT(*) color is white.
*: For cold regions
Bio grease
G2-B SYG2-400B
SYGA-16CNB 400 g Bellows-type • Since this grease is biodegradable in
G2-BT (*) container short period, it has less impact on
*: For use at high SYG2-400BT(*) 16 kg microorganisms, animals, and plants.
Can
temperature and SYGA-16CNBT(*)
under high load
• Silicone grease with wide usable
temperature range, high resistance to
G2-S thermal-oxidative degradation and
— 200 g Tube performance to prevent deterioration
ThreeBond 1855 of rubber and plastic parts
• Use for oil seals of the transmission,
etc.
• Urea (organic system) grease with
heat resistance and long life.
Enclosed type.
G2-U-SENS
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
grease
damper.
Caution: Do not mix it with lithium
grease.
50-8 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Primer
Komatsu code Part No. Capacity Container Main features and applications
Glass • Use to accelerate hardening of
Loctite 712 428-99-80080 100 ml
container instantaneous adhesive.
• Use as primer for painted cab
Sunstar Paint Glass sheet metal surface.
Primer 580 Super 20 ml (Effective period: 4 months after
container
manufacture)
417-926-3910
• Use as primer for cab glass
Sunstar Glass Glass surface.
20 ml
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use "S" in high temperature
season and "W" in low
Sunstar Penguin
For adhering cab glass
Caulking material
Komatsu code Part No. Capacity Container Main features and applications
• Use to seal joints of glass parts.
Sunstar Penguin Polyethylene
For adhering cab glass
WA470-7 50-9
50 Disassembly and assembly
General information on disassembly and assembly
a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tools.
a New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
a Tools marked with Q in the Sketch column have the sketches. (See "Sketches of special tools")
New/Redesign
Necessity
Sketch
Details of work and
Q'ty
Work Symbol Part No. Part name
remarks
50-10 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
New/Redesign
Necessity
Sketch
Details of work and
Q'ty
Work Symbol Part No. Part name
remarks
WA470-7 50-11
50 Disassembly and assembly
General information on disassembly and assembly
New/Redesign
Necessity
Sketch
Details of work and
Q'ty
Work Symbol Part No. Part name
remarks
50-12 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
New/Redesign
Necessity
Sketch
Details of work and
Q'ty
Work Symbol Part No. Part name
remarks
WA470-7 50-13
50 Disassembly and assembly
General information on disassembly and assembly
New/Redesign
Necessity
Sketch
Details of work and
Q'ty
Work Symbol Part No. Part name
remarks
50-14 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
New/Redesign
Necessity
Sketch
Details of work and
Q'ty
Work Symbol Part No. Part name
remarks
7 790-101-2560 Nut t 2
8 790-101-2740 Adapter t 2
Removal of axle shaft
D17 9 790-201-1410 Plate t 1 and bearing
10 790-101-2102 Puller assembly t 1
11 790-101-1102 Hydraulic pump t 1
1 790-101-2800 Bearing puller t 1
Removal of axle shaft
D18 2 793T-622-2530 Bolt t 2 Q bearing
3 01643-32060 Washer t 2
Disassembly and Press fit of outer races
assembly of axle D19 793T-622-2540 Spacer q 1 Q into axle housing
housing assembly Press fit of outer races
D20 793T-622-2550 Spacer q 1 Q into axle housing
1 793T-622-1330 Push tool t 1 Q Press fit of oil seal and
D21
2 793T-622-1340 Spacer t 1 Q bearing into axle shaft
1 793T-622-1370 Support t 2 Q Adjusting the installed
D22 position of oil seal
2 01010-50830 Bolt t 6
Press fit of axle shaft
D23 793T-622-2510 Spacer t 1 Q into bearing
D24 793T-622-1510 Holder t 1 Q Selection of shims
Disassembly and
assembly of axle
housing assembly Measurement of starting
D25 79A-264-0021 Push-pull scale q 1 torque
Disassembly and
assembly of
differential assembly
1 790-101-2300 Push puller t 1
2 793-520-2370 Push tool t 1
3 793-520-2350 Push tool t 1
Removal and t
4 793-520-2540 Guide 1 Installation of upper
installation of center E1
5 793-520-2360 Bar t 2 hinge pin
hinge pin
6 791-112-1180 Nut t 2
7 790-101-1102 Hydraulic pump t 1
8 790-101-2102 Puller (30 ton) t 1
1 790-502-1003 Repair stand t 1 Disassembly and
F1 assembly of hydraulic
2 790-101-1102 Hydraulic pump t 1 cylinder assembly
Socket
For steering cylinder
F2 790-302-1280 (width across flats: t 1
piston nut
55 mm)
1 790-330-1100 Wrench assembly t 1 For steering cylinder
Disassembly and F3
2 790-102-2304 Wrench assembly t 1 cylinder head
assembly of hydraulic
cylinder assembly 1 790-102-4300 Wrench assembly t 1 For lift cylinder and
F4 bucket cylinder piston
2 790-102-4310 Pin t 1
1 790-720-1000 Expander t 1
2 796-720-1650 Ring t 1
F5 3 07281-01029 Clamp t 1 For piston ring assembly
4 796-720-1680 Ring t 1
5 07281-01589 Clamp t 1
WA470-7 50-15
50 Disassembly and assembly
General information on disassembly and assembly
New/Redesign
Necessity
Sketch
Details of work and
Q'ty
Work Symbol Part No. Part name
remarks
50-16 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A6: Bracket
WA470-7 50-17
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A11-1: Push tool
50-18 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A11-3: Push tool
WA470-7 50-19
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A11-5: Guide
A11-6: Spacer
50-20 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A15: Push tool
A16: Installer
WA470-7 50-21
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B1: Bracket
B2: Plate
50-22 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B3: Plate
WA470-7 50-23
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B6: Lifting tool
B6: Bar
50-24 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B7: Plate
WA470-7 50-25
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B8: Bracket
B8: Plate
50-26 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B9: Bolt
B10: Sleeve
WA470-7 50-27
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B15: Push tool
50-28 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B18: Push tool
WA470-7 50-29
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B20: Push tool
50-30 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B24: Push tool
WA470-7 50-31
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B30: Spacer
50-32 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B32: Spacer
B33: Plate
WA470-7 50-33
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B38: Spacer
50-34 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B49: Seal holder
WA470-7 50-35
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B52: Seal holder
50-36 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B54: Seal holder
D1-3: Plate
WA470-7 50-37
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D2: Eyebolt
50-38 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D5-2: Spacer
WA470-7 50-39
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D9-1 and D10-1: Push tool
D10-2: Spacer
50-40 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D11: Push tool
D12-1: Wrench
WA470-7 50-41
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D17-1: Block
D18-2: Bolt
50-42 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D19: Spacer
D20: Spacer
WA470-7 50-43
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D21-1: Push tool
D21-2: Spacer
50-44 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D22-1: Support
D23: Spacer
WA470-7 50-45
50 Disassembly and assembly
General information on disassembly and assembly
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D24: Holder
50-46 WA470-7
50 Disassembly and assembly
Engine and cooling system
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
WA470-7 50-47
50 Disassembly and assembly
Engine and cooling system
50-48 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-49
50 Disassembly and assembly
Engine and cooling system
Installation (WA470-AD70-720-K-00-A)
50-50 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-51
50 Disassembly and assembly
Engine and cooling system
[*2]
3 Overflow valve (9):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
[*3]
3 Joint bolt (14):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
[*4]
a Install joint bolts (16) and (18) while confirming
discrimination mark put at disassembly.
3 Joint bolts (16) and (18):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
[*5]
3 Joint bolt of fuel tube (20) (supply pump
side):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
3 Joint bolt of fuel tube (20) (fuel filter
side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*6]
3 Cover (33) mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
• Air bleeding
Bleed air in the fuel system. For details, see
Testing and adjusting, "Bleeding air in circuit".
• Checking for fuel leakage
Check for fuel leakage. For details, see Testing
and adjusting, "Testing fuel circuit for leakage".
50-52 WA470-7
50 Disassembly and assembly
Engine and cooling system
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
A4 6212-82-0110 Wrench t 1
4 Bracket (2):
40 kg
WA470-7 50-53
50 Disassembly and assembly
Engine and cooling system
• VGT-REV(16)
• SVGT(17)
• PDOSER(18)
• SOV1(19)
• SOV2(20)
7. Remove bracket (21).
8. Remove tubes (22) and (23).
50-54 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-55
50 Disassembly and assembly
Engine and cooling system
Installation (WA470-AE60-720-K-00-A)
50-56 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-57
50 Disassembly and assembly
Engine and cooling system
3. Install locker arm and shaft assembly according 5. Install the O-ring and cylinder head cover (33).
to the following procedure.
a Installing the O-ring without a twist.
1) Set rocker arm and shaft assembly (39).
3 Mounting bolt:
a Install the rocker arm shaft (50) with its
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
larger mounting hole end down and with
its ball plug (51) side facing to front of
engine.
2) Check that the ball of adjustment screw (41)
is fitted in push rod socket (52) and tighten
mounting bolt (38).
a Clean the oil hole of mounting bolt (38)
and install it.
3 Mounting bolt (38):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
3) Adjust the valve clearance. For details, see
Testing and adjusting, "Testing and adjusting
valve clearance". 6. Install the high-pressure fuel pipes according to
the following procedure.
50-58 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-59
50 Disassembly and assembly
Engine and cooling system
50-60 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-61
50 Disassembly and assembly
Engine and cooling system
[*1]
3 Sleeve nut of fuel hose (5):
14.7 ± 4.9 Nm {1.5 ± 0.5 kgm}
[*2]
3 Joint bolt of coolant hose (6):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
a After installing the fuel doser assembly, run the
engine at low idle for approximately 3 minutes.
Then stop the engine and check the fuel doser
for water and fuel circuits for leakage.
50-62 WA470-7
50 Disassembly and assembly
Engine and cooling system
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
5790-331-1110 Wrench q 1
793T-601-1410 Bracket t 1
A 01011-81040 Bolt t 2
6
01643-31032 Washer t 2
01580-01008 Nut t 2
• VGT-SOL (9)
4 Bracket (2):
40 kg
WA470-7 50-63
50 Disassembly and assembly
Engine and cooling system
• INJ (12)
• DOSER (13) 11.Disconnect hose (27), and remove fuel prefilter
• PAMB (14) (28). [*3]
• SVGT (15) 12.Remove fuel tubes (29) and (30). [*4]
• VGT-REV (16) 13.Remove filter head assembly (31).
• PDOSER (17)
• SOV1 (18)
• PCCV (19)
50-64 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-65
50 Disassembly and assembly
Engine and cooling system
50-66 WA470-7
50 Disassembly and assembly
Engine and cooling system
41.Remove exhaust tube (68). [*16] 47.Remove covers (81) and (82).
WA470-7 50-67
50 Disassembly and assembly
Engine and cooling system
50-68 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-69
50 Disassembly and assembly
Engine and cooling system
71.Remove mounting bolts, sling cylinder head 2 Cylinder head mounting bolt
assembly (125), and remove it. (threaded part and seat surface):
Molybdenum disulphide lubricant
4 Cylinder head assembly (125): (LM-P) or engine oil
20 kg 3 Cylinder head mounting bolt:
1st time: 98 ± 9.8 Nm {10 ± 1 kgm}
2nd time: 166.6 to 176.4 Nm {17 to
18 kgm}
(Target: 176.4 Nm {18 kgm})
3rd time: By using tool A5,
retighten the bolt by 90 to 120
degrees.
(Target: 120 degrees)
Installation (WA470-A100-720-K-00-A)
50-70 WA470-7
50 Disassembly and assembly
Engine and cooling system
3 Hose clamp:
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
[*2]
a Install tubes (23) and (24) according to the
following procedure.
1. Tighten the mounting bolts of the oil filter bracket
lightly.
2. Install tubes (23) and (24), and tighten bolt (A)
and (B) lightly.
3. Tighten bolts (B) and (A) in this order to the
specified torque.
4. Tighten the mounting bolts of the oil filter bracket
a If tool A5 is not used, put mark (b) on to the specified torque.
cylinder head and bolt with paint etc., and 5. Install cushion (C) and fasten clamp (D).
retighten bolt by 90 to 120 degrees a Install cushion (C) so that slit position (a)
(target 120 degrees). faces outside of clamp (D).
3) After tightening, put a punch mark (c) on
each bolt head to indicate the number of
tightening.
a When a new bolt is used, do not put a
punch mark on its head.
[*3]
a After the packing touches the seal surface,
tighten fuel prefilter (28) by 1/2 to 3/4 turns.
2 Packing: Engine oil
[*4]
a Install tubes (29) and (30) according to the
following procedure.
1. Loosen elbow (A) at filter head side and elbow
(B) at merge-divider block side in advance.
3. Perform the subsequent installation in the
2. Install tubes (29) and (30), and fasten the sleeve
reverse order to removal.
nuts on both ends.
[*1]
WA470-7 50-71
50 Disassembly and assembly
Engine and cooling system
3 Sleeve nut:
43 to 47 Nm {4.4 to 4.8 kgm}
3. Secure elbows (A) and (B) to prevent them from
rotation, and tighten the nuts.
3 Nut:
84 to 132 Nm {8.5 to 13.5 kgm}
[*9]
3 Hose clamp:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
50-72 WA470-7
50 Disassembly and assembly
Engine and cooling system
[*10]
3 Joint bolt of tubes (44) and (45) (cylinder
block side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint bolt of tubes (44) and (45) (KCCV
side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*11]
a Adjust the air conditioner compressor belt
tension. For details, see Testing and adjusting,
"Testing and adjusting air conditioner
compressor belt tension". [*15]
[*12] a Tighten the intake manifold mounting bolts in the
3 Terminal E07B(52): order shown in the figure.
5.88 to 7.84 Nm {0.6 to 0.8 kgm} 3 Air intake manifold mounting bolt:
[*13] 59 to 74 Nm {6.0 to 7.5 kgm}
3 Joint bolt of tube (54) (both ends):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Tube (55) joint bolt:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
3 Sleeve nut of tube (55):
24 to 27 Nm {2.4 to 2.7 kgm}
[*14]
a Install the hose and clamp at aftercooler side in
the dimensions as follows.
• Dimensions (a) and (b): 10 mm
• Dimension (c): 75 mm [*16]
• Angle (d): 35 degrees
a Install exhaust tube (68) according to the
3 Clamp: following procedure.
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} 1. Remove plug (A).
a Install the hose and clamp at intake connector 2. Install tool (A6) to exhaust connector (B).
side in the dimensions as follows. 3. Install exhaust tube (68) to exhaust connector
(B) loosely.
• Dimension (e): 75 mm
• Dimensions (f) and (g): 10 mm 2 Thread part of bolt at exhaust
connector side:
3 Clamp:
Seizure prevention compound (LC-G)
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
WA470-7 50-73
50 Disassembly and assembly
Engine and cooling system
[*17]
a Set clamp (72) to level, adjust the direction of
clamp, and tighten it to the following torque.
3 Clamp (72):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*19]
a Install clamps (2 pieces) of hose (78) with its
screws to be same direction.
3 Clamp of hose (78):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*18]
a Install clamps (both ends) of hose with its
screws to be opposite direction (shifted by 180
degrees).
a Install hose and clamp at KVGT side in the
dimensions as follows.
[*20]
• Dimensions (a) and (b): 10 mm
• Dimension (c): 75 mm a Apply seizure prevention compound (LC-G) to
mounting bolts (A) of bracket (83).
50-74 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-75
50 Disassembly and assembly
Engine and cooling system
[*32]
a Adjust the crosshead according to the following
procedure.
1. Loosen lock nut (126) and back off adjustment
screw (127).
2. While pressing the top of crosshead (123) lightly,
tighten adjustment screw (127).
3. When adjustment screw (127) touches the valve
stem, tighten it further by 20 degrees.
4. With the adjustment screw in this position,
tighten lock nut (126).
2 Crosshead guide and top of
crosshead:
Engine oil
3 Lock nut (126):
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
[*33]
3 Rocker housing mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
• Adjust the valve clearance. For details, see
Testing and adjusting, "Adjusting valve
clearance".
• Refilling of coolant (radiator)
Refill with the coolant to the specified level
through the water filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.
5 Radiator:
75 l
50-76 WA470-7
50 Disassembly and assembly
Engine and cooling system
Removal (WA470-H540-520-K-00-A)
WA470-7 50-77
50 Disassembly and assembly
Engine and cooling system
a Remove the mounting bolts on the other side • Perform installation in the reverse order of
as well. removal.
50-78 WA470-7
50 Disassembly and assembly
Engine and cooling system
4 Cover (2):
70 kg 5. Open full-length fender (5) on the right and left
side of the machine body, and then open side
cover (6).
WA470-7 50-79
50 Disassembly and assembly
Engine and cooling system
6. Remove frame (7) on the left side of the 12.Remove mounting bolt (13) at the top of the
machine body. engine hood.
7. Remove clamp (8).
a Remove them on the other side in the same
8. Remove the mounting bolts of cover (9).
way.
50-80 WA470-7
50 Disassembly and assembly
Engine and cooling system
4 Grille assembly:
130 kg
Installation (WA380-H54E-720-K-00-A)
WA470-7 50-81
50 Disassembly and assembly
Engine and cooling system
k Place the machine on a level ground, and 7. Remove brackets (5) and (6).
turn the parking brake switch to ON position.
Removal (WA470-B000-520-K-00-A)
6 Radiator:
75 l
2. Remove the grille assembly. For details, see
"Removal and installation of grille assembly".
3. Remove the aftercooler. For details, see
"Removal and installation of aftercooler."
4. Disconnect radiator lower hose (1). [*1]
5. Disconnect hose (2) from hydraulic oil cooler
piping. 9. Remove clamp (8) on the left side of the
machine.
50-82 WA470-7
50 Disassembly and assembly
Engine and cooling system
[*2]
12.Remove the mounting bolts(3 pieces each) on
a When installing the clamps of hose (9), set the
the right and left, sling cooling system assembly
screws 180 degrees apart from each other in the
(13), and remove it.
dimensions as follows.
4 Cooling system assembly (13): • Dimension (a): 55.5 mm
• Dimension (b): 9 mm
400 kg • Dimension (c): 5 mm
2 Hose (9) insertion portion:
Liquid gasket (LG-10)
3 Clamp of hose:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
Installation (WA470-B000-720-K-00-A)
WA470-7 50-83
50 Disassembly and assembly
Engine and cooling system
5 Radiator:
75 l
50-84 WA470-7
50 Disassembly and assembly
Engine and cooling system
k Turn the battery disconnect switch to OFF 8. Sling radiator core assembly (13), and remove it.
position, and remove the key. (For details, a Remove the assembly on the other side in
see Testing and adjusting, "Handling battery the same way.
disconnect switch".)
4 Radiator core assembly (13):
Removal (WA470-B222-520-K-00-A)
40 kg
1. Remove the cooling system assembly (1) and
stably place it on block [1]. For details, see
"Removal and installation of cooling system
assembly".
2. Remove hoses (2) and (3). [*1]
Installation (WA470-B222-720-K-00-A)
WA470-7 50-85
50 Disassembly and assembly
Engine and cooling system
[*1] [*2]
a When installing the clamps of hoses (2) and (8),
set the screws 180 degrees apart from each
other, in the direction as follows.
• Hose (2): Toward the bottom
• Hose (8): Toward the top
a Install hoses (2), (8) and their clamps in the
dimensions as follows.
a The figure shows an example of hose (8). Note
that the dimensions are the same as those of
hose (2).
• Dimensions (a) and (d): 9 mm
• Dimensions (b) and (c): 4 mm
• Dimensions (e) and (f): 53.5 mm
2 Insertion portion (both ends) of hoses (2)
and (8):
Liquid gasket (LG-10)
3 Clamps (both ends) of hoses (2) and (8):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
50-86 WA470-7
50 Disassembly and assembly
Engine and cooling system
k Turn the battery disconnect switch to OFF 3. Remove air conditioner condenser assembly (1).
position, and remove the key. (For details, For details, see "Removal and installation of air
see Testing and adjusting, "Handling battery conditioner condenser assembly".
disconnect switch".) a Do not disconnect hoses (2) and (3)
4. Remove cover (4) and move air conditioner
Removal (WA470-A9A0-520-K-00-A)
condenser assembly (1) toward the engine side.
1. Remove caps (A) (8 pieces) of the engine upper
cover and inner bolts (8 pieces).
a Remove the caps and bolts indicated by the
arrows.
a Do not remove the bolts marked with e.
(Otherwise, the door hinge is removed and
adjustment during installation process
becomes difficult.)
4 Cover (B):
70 kg
WA470-7 50-87
50 Disassembly and assembly
Engine and cooling system
Installation (WA470-A9A0-720-K-00-A)
4 Aftercooler:
25 kg
[*2]
a Install hose and the clamp in the dimensions
as follows.
• Dimensions (a) and (b): 10 mm
• Dimension (c): 75 mm
• Angle (d): 35 degrees
3 Clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
50-88 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-89
50 Disassembly and assembly
Engine and cooling system
Removal (WA470-B8P0-520-K-00-A)
6 Hydraulic tank:
173 l
2. Open full-length fender (1) and side cover (2).
a Perform the same work on the opposite side.
50-90 WA470-7
50 Disassembly and assembly
Engine and cooling system
Installation (WA470-B8P0-720-K-00-A)
5 Hydraulic tank:
173 l
WA470-7 50-91
50 Disassembly and assembly
Engine and cooling system
k Turn the battery disconnect switch to OFF 5. Open full-length fender (3) on the right and left
position, and remove the key. (For details, side of the machine body, and then open side
see Testing and adjusting, "Handling battery cover (4).
disconnect switch".)
Removal (WA470-B850-520-K-00-A)
6 Radiator: 75 l
2. Drain the power train oil.
6 Transmission case: 65 l
3. Remove caps (1) (8 pieces) of the engine upper
cover and inner bolts (8 pieces).
a Remove the caps and bolts indicated by the
arrows. 6. Disconnect hose (5). [*1]
a Do not remove the bolts marked with e. 7. Remove covers (6) to (8).
(Otherwise, the door hinge is removed and 8. Remove bolts (9) to (11) and move the bracket
adjustment during installation process and piping together as a unit.
becomes difficult.) 9. Disconnect hose (11-1).
4 Cover (1):
70 kg
50-92 WA470-7
50 Disassembly and assembly
Engine and cooling system
10.Remove bracket (12) (2 pieces) mounting bolts, 17.Remove mounting bolts (21).
and remove receiver drier (13). 18.Remove the clamps of hoses (22) and (23), and
11.Remove clamp (14), and disconnect hose (15). pull out power train oil cooler assembly (24) from
12.Disconnect hose (16). the hose. [*3]
13.Remove clamp (17), and move hose (16).
14.Disconnect hose (18).
WA470-7 50-93
50 Disassembly and assembly
Engine and cooling system
Installation (WA470-B850-720-K-00-A)
[*3]
• Perform installation in the reverse order of
removal. a When installing the clamps of hose (22), set the
[*1] screws 180 degrees apart from each other.
a When installing the clamps of hose, set the a Install hose (22) and the clamp in the
screws 180 degrees apart from each other. dimensions as follows.
• Dimensions (a) and (b): 10 mm
a Install hose and the clamp in the dimensions as
• Dimension (c): 65 mm
follows.
• Dimension (d): 75 mm 2 Hose (22) insertion portion:
• Dimensions (e) and (f): 10 mm Liquid gasket (LG-10)
3 Clamp of hose (22):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
a When installing the clamps of hose, set the
screws 180 degrees apart from each other, in • Refilling of oil
the direction as follows. Refill with oil to the specified level through the oil
• Radiator side: Toward the bottom filler port. Run the engine to circulate the power
• Power train oil cooler side: Toward the top
50-94 WA470-7
50 Disassembly and assembly
Engine and cooling system
5 Transmission case:
65 l
• Refilling with coolant
Refill with the coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.
5 Radiator: 75 l
WA470-7 50-95
50 Disassembly and assembly
Engine and cooling system
k Turn the battery disconnect switch to OFF 5. Remove clamp (6) on the front right of the fuel
position, and remove the key. (For details, tank.
see Testing and adjusting, "Handling battery 6. Remove mounting bolt (7) of drain hose.
disconnect switch".)
Removal (WA470-A000-520-K-00-A)
6 Radiator:
75 l
2. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood
assembly".
3. Disconnect connectors ER2 (1), ER1 (2) and
ER3 (3) at the bottom of the hydraulic tank on
the left side of the machine body.
7. Disconnect hose (8). [*1]
4. Disconnect terminals (4) and (5) and remove the 8. Disconnect connector E28 (9).
harness clamp on the side of the engine on the 9. Remove fuel feed pump (10) and bracket (10)
left side of the machine body. together as a unit.
10.Remove cover (11).
50-96 WA470-7
50 Disassembly and assembly
Engine and cooling system
11.Disconnect fuel hoses (12) and (13). 16.Disconnect hose (21) and ground cable (22).
13.Remove clamps (16) and (17). 18.Disconnect connector CAN1 (24) on the side of
14.Disconnect hose (18). the engine on the right side of the machine.
15.Disconnect terminal E07A (19) and connector 19.Disconnect hoses (25) to (27). [*2]
ER4 (20).
WA470-7 50-97
50 Disassembly and assembly
Engine and cooling system
4 Damper (33):
15 kg
50-98 WA470-7
50 Disassembly and assembly
Engine and cooling system
26.Disconnect terminals E02 (35) and E04 (36), 32.Sling the engine assembly.
and remove the harness clamp. 33.Remove connection bolts (42) (12 pieces)
between the engine and transmission.
WA470-7 50-99
50 Disassembly and assembly
Engine and cooling system
50-100 WA470-7
50 Disassembly and assembly
Engine and cooling system
a When installing the clamps of hose (26), set the a Install hose (27) and the clamp on the engine
screws 180 degrees apart from each other. side in the dimensions as follows.
a Install hose (26) and the clamp in the • Dimension (d): 58 mm
dimensions as follows. • Dimension (e): 5 mm
• Dimension (f): 10 mm
• Dimension (a): 10 mm
• Dimension (b): 7 mm
• Dimension (c): 60 mm
2 Hose (26) insertion portion:
Liquid gasket (LG-10)
3 Clamp of hose (26):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
3 Damper (33) mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*4]
a Install cushion (45) of the engine mount portion
with its mark (a) facing to the outside of machine
body.
a When installing the clamps (both ends) of hose
(27), set the screws 180 degrees apart from 3 Engine mount mounting bolt:
each other. 455 to 565 Nm {46.5 to 58 kgm}
2 Hose (27) insertion portion (both ends):
Liquid gasket (LG-10)
3 Clamp of hose (27):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
a Install hose (27) and the clamp on the radiator
side in the dimensions as follows.
• Dimension (a): 55.5 mm
• Dimension (b): 9 mm
• Dimension (c): 5 mm
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.
5 Radiator:
75 l
WA470-7 50-101
50 Disassembly and assembly
Engine and cooling system
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
50-102 WA470-7
50 Disassembly and assembly
Engine and cooling system
a Perform this work evenly at several a Take care not to let oil seal lip (a) get
places so that engine front oil seal (6) is caught on crankshaft (8).
not tilted. 2 Engine front oil seal (8) (50 to 80 %
of lip space volume):
Grease (G2-LI)
• Tool A7
WA470-7 50-103
50 Disassembly and assembly
Engine and cooling system
50-104 WA470-7
50 Disassembly and assembly
Engine and cooling system
a Special tools
Necessity
Q'ty
Symbol Part No. Part name
Seal puller
7 795-931-1100 assembly q 1
1 795T-401-1310 Push tool t 1
2 795T-401-1320 Guide bolt t 3
3 795T-601-1310 Push tool t 1
11
4 795T-401-1330 Push tool t 1
A 5 795T-401-1340 Guide t 1
4. Remove rear oil seal (4) according to the
6 795T-401-1350 Spacer t 1 following procedure.
Bolt: (M16 x 2.0,
1 01010-61660 stem length: 60) t 1 1) Slightly tap rear oil seal (4) to unstick it from
12 flywheel housing (5).
Bolt: (M16 x 2.0,
2 01010-61640 stem length: 40) t 1
13 01643-31645 Washer (t = 4.5) t 1
k Turn the starting switch to OFF position, and 2) If the seal is sleeved, cut sleeve (7), and
stop the engine. remove it by using a chisel and a hammer.
k Turn the battery disconnect switch to OFF a Be careful not to damage crankshaft (6).
position, and remove the key. (For details, 3) Hang the tip of tool A7 on the metal ring of
see Testing and adjusting, "Handling of rear oil seal (4), and remove the seal by
battery disconnect switch".) using impact power of slide hammer (SH).
(Perform this work evenly so that the rear oil
Removal (WA470-A510-520-K-00-A) seal is not tilted.)
1. Remove the engine assembly. For details, see a Do not use a drill as metal chips may
"Removal and installation of engine assembly". enter the engine.
2. Sling flywheel (1), and install guide bolt [1]. a If any chips are generated, remove them
3. Remove mounting bolt (2), pull out flywheel (1), completely.
and remove it. [*1]
• Tool A7
4 Flywheel (1):
30 kg
WA470-7 50-105
50 Disassembly and assembly
Engine and cooling system
a Seal type is double seal (Inside of a Clean, degrease, and dry the contacting
flywheel housing is wet). surface against flywheel housing (5).
a The left one in the following figure shows a Before installing rear oil seal (4), ensure that
the standard oil supply seal and the right the end corner and lip sliding surface of the
one shows the sleeved seal. crankshaft, and flywheel housing (5) are free
from scratches, burrs, sharp fins, rust, etc.
a When installing rear oil seal (4), do not apply
oil or grease to the crankshaft and seal lip
surface (around the crankshaft). Thoroughly
wipe off oil or grease from the crankshaft.
Installation (WA470-A510-720-K-00-A)
a If the wear depth of the shaft is 10 mm or less a Before installing the oil seal, check that
and no scratch is present, install "standard the end corner and oil seal lip sliding
seal (A)". Otherwise, install "sleeved seal surface of the crankshaft and the housing
(B)". are free from scratches, sharp fins, burrs,
rust, etc.
• (8): Inner plastic tube/installation guide
• (7): Sleeve a When installing the oil seal, do not apply
oil or grease to the crankshaft and seal lip.
a Do not remove inner plastic tube/installation Thoroughly wipe off oil or grease from the
guide (8) before installing rear oil seal (4). crankshaft.
a Handle sleeve (7) and rear oil seal (4) as an a Never remove the inner plastic tube of the
assembly and never separate them from standard seal of spare part just before
each other. installation.
a The left one in the following figure shows the 1] Install tool A11-1 to the rear end of
standard seal and the right one shows the crankshaft, and screw in tool A11-2 (3
sleeved seal. pieces) lightly.
a At this stage, tool A11-2 has a little
play.
50-106 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-107
50 Disassembly and assembly
Engine and cooling system
50-108 WA470-7
50 Disassembly and assembly
Engine and cooling system
a Wipe off the dirt in the sealant applied • Facial runout: Max. 0.17 mm
to periphery of the seal. • Radial runout: Max. 0.13 mm
WA470-7 50-109
50 Disassembly and assembly
Engine and cooling system
Removal (WA470-B5L0-520-K-00-A)
50-110 WA470-7
50 Disassembly and assembly
Engine and cooling system
Installation (WA470-B5L0-720-K-00-A)
WA470-7 50-111
50 Disassembly and assembly
Engine and cooling system
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
Removal (WA470-A9H0-520-K-00-A)
50-112 WA470-7
50 Disassembly and assembly
Engine and cooling system
5. Open full-length fender (5) on the right and left 8. Remove tube (10).
side of the machine body, and then open side 9. Remove mounting bolts (11) (8 pieces) of KDPF
cover (6). assembly bracket.
6. Remove covers (7) and (8) on the the right and 10.Disconnect connectors E25 (12) and E26 (13) at
left sides of the engine. the top of KDPF assembly.
WA470-7 50-113
50 Disassembly and assembly
Engine and cooling system
12.Place the KDPF assembly on a level ground. 2. Tighten bolts (16) (4 pieces).
13.Remove exhaust pipe (15).
Installation (WA470-A9H0-720-K-00-A)
50-114 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-115
50 Disassembly and assembly
Engine and cooling system
50-116 WA470-7
50 Disassembly and assembly
Engine and cooling system
1. Preparation
1) Use lifting tool [1] to lift KDPF assembly (1). 2) Mark at 3 points (a), (b), and (c) of each body
Place blocks [2] to 4 places under it to connection.
support the assembly securely. • (A): Connection between inlet and KDOC
• (B): Connection between KDOC and
4 KDPF assembly (1): KCSF
70 kg • (C): Connection between KCSF and
a Place block [2] at a position where it does outlet
not touch the piping and bands of the a These marks are required to facilitate
KDPF. angle adjustment of KDPF inlet and outlet
a Place cloth or the like on the supporting flanges in assembly work.
portion of block [2] to prevent damage on • (2): Inlet body
the KDPF. • (3): KDOC body
• (4): KCSF body
a Dimensions of blocks [2] are shown in the • (5): Outlet body
following figure.
WA470-7 50-117
50 Disassembly and assembly
Engine and cooling system
50-118 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-119
50 Disassembly and assembly
Engine and cooling system
50-120 WA470-7
50 Disassembly and assembly
Engine and cooling system
5. Body
a Before removing each body, record the
mounting position of each harness bracket.
1) Place blocks [2] at 4 places under them to
support the assembly securely.
2) Remove mounting bolts (33) (12 pieces) at
8) Remove differential pressure sensor pipes each connection between bodies, and then
(25) and (27). remove backup plate (34) and hangers (36)
and (37).
a To remove differential pressure sensor
• Width across flats of mounting bolt (33):
pipes (25) and (27), vertically pull them
14 mm
out because those pipes are inserted in
3) Remove harness bracket (38).
the KCSF and outlet body.
4) Disconnect inlet body (2), KDOC body (3),
KCSF body (4), and outlet body (5).
a Support KDOC body (3) with your hand
because its lower part is not supported
with blocks [2].
5) Remove gaskets (35) from between the
bodies.
a Discard gaskets (35) because reuse of the
gaskets is not allowed.
WA470-7 50-121
50 Disassembly and assembly
Engine and cooling system
50-122 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-123
50 Disassembly and assembly
Engine and cooling system
50-124 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-125
50 Disassembly and assembly
Engine and cooling system
k Place the machine on a level ground, and 8. Remove mounting bolts (4 pieces), and remove
turn the parking brake switch to ON position. KCCV assembly (9).
[*2]
3 Clamp of blowby hose (6):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
[*3]
3 Joint bolt of tubes (7) and (8) (KCCV
side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
4. Disconnect connector PCCV (4).
3 Joint bolt of tubes (7) and (8) (cylinder
5. Disconnect hose (5). [*1]
block side):
6. Disconnect blowby hoses (6) (2 pieces) on the
tube side. [*2] 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
7. Remove the joint bolt and clamp of tubes (7) and • Refilling with coolant
(8). [*3] Refill with the coolant to the specified level
through the coolant filler port. Run the engine to
50-126 WA470-7
50 Disassembly and assembly
Engine and cooling system
5 Radiator: 75 l
WA470-7 50-127
50 Disassembly and assembly
Engine and cooling system
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
Removal (WA470-AA10-520-K-00-A)
5. Remove heat insulation cover (3).
1. Drain the coolant. 6. Remove cover (4) and bracket (5).
6 Radiator: 75 l
2. Remove caps (A) (8 pieces) of the engine upper
cover and inner bolts (8 pieces).
a Remove the caps and bolts indicated by the
arrows.
a Do not remove the bolts marked with e.
(Otherwise, the door hinge is removed and
adjustment during installation process
becomes difficult.)
4 Cover (B): 70 kg
50-128 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-129
50 Disassembly and assembly
Engine and cooling system
3 Clamp of hose:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*3]
2 Bolt (20):
Seizure prevention compound (LC-G)
3 Bolt (20):
78.5 to 88.3 Nm {8 to 9 kgm}
[*4]
Installation (WA470-AA10-720-K-00-A)
2 Mounting bolt of bracket (21):
Seizure prevention compound (LC-G)
• Perform installation in the reverse order to
removal. 3 Mounting bolt of bracket (21):
[*1] 68.6 to 73.5 Nm {7.0 to 7.5 kgm}
a Install hose and clamp in the dimension as [*5]
follows.
3 Joint bolt (22):
• Dimension (a): 40 mm
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
• Dimension (b): 10 mm
[*6]
50-130 WA470-7
50 Disassembly and assembly
Engine and cooling system
a Install clamps (both ends) of hose (27) with its 2. By using tool A15, install seal (37) to oKVGT
screws to be same direction. housing (36).
3 Clamp of hose (27): a Drive in tool A15 until it touches flange
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} surface (c) of KVGT housing (36).
a Clearance (d) between KVGT housing (36)
and seal (37) becomes following dimension.
• Clearance (d): 3 mm
[*7]
3 Joint bolt (29):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3. Install bracket (21).
3 Sleeve nut at front cover side of tubes
(30) and (31): a Lightly tighten the mounting bolts.
24 to 27 Nm {2.4 to 2.7 kgm} 2 Mounting bolt of bracket (21):
[*8] Seizure prevention compound (LC-G)
3 Sleeve nut of tube (32): 4. Install plug (38) to exhaust connector (35).
24 to 27 Nm {2.4 to 2.7 kgm} 3 Plug (38):
3 Tube (32) joint bolt: 2.9 to 5.9 Nm {0.3 to 0.6 kgm}
5. Install seal ring (39) to exhaust connector (35).
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*9] a Install seal ring (39) with its stamp mark (R)
facing the KVGT housing.
2 KVGT assembly (34) mounting bot and 6. Fix tool A16 to exhaust connector (35) with bolt
nut: [1].
Seizure prevention compound (LC-G) 7. Install exhaust connector (35) to KVGT housing
(36).
3 KVGT assembly (34) mounting bot and
nut: a Push in tool A16 until its end face touches
68.6 to 73.5 Nm {7 to 7.5 kgm} flange surface (c) of KVGT housing (36).
8. Fix KVGT housing (36) and tool A16 with bolt
a When exhaust connector (35) is removed, install [2].
it according to the following procedure.
a Check that dimensions (e) and (f) are the
following value.
• Dimension (e): 129 mm
• Dimension (f): 19 mm
9. Tighten bolt (40).
10.Tighten the mounting bolts of bracket (21) to the
specified torque.
3 Mounting bolt of bracket (21):
68.6 to 73.5 Nm {7.0 to 7.5 kgm}
11.Remove tool A16.
WA470-7 50-131
50 Disassembly and assembly
Engine and cooling system
5 Radiator: 75 l
50-132 WA470-7
50 Disassembly and assembly
Engine and cooling system
k Turn the battery disconnect switch to OFF 5. Remove connecting bolts (9) (4 pieces) from
position, and remove the key. (For details, tube (8).
see Testing and adjusting, "Handling of 6. Remove mounting bolts (2 pieces), and remove
battery disconnect switch".) EGR valve assembly (10).
Removal (WA470-A9K1-520-K-00-A)
Installation (WA470-A9K1-720-K-00-A)
WA470-7 50-133
50 Disassembly and assembly
Engine and cooling system
k Turn the battery disconnect switch to OFF 5. Remove tubes (6) and (7). [*2]
position, and remove the key. (For details, 6. Remove tubes (8) to (10). [*3]
see Testing and adjusting, "Handling of a To remove tube (9), remove the upper joint
battery disconnect switch".) bolt.
Removal (WA470-A9L0-520-K-00-A)
6 Radiator: 75 l
2. Open full-length fender (1), and side cover (2).
50-134 WA470-7
50 Disassembly and assembly
Engine and cooling system
Installation (WA470-A9L0-720-K-00-A)
5 Radiator: 75 l
WA470-7 50-135
50 Disassembly and assembly
Engine and cooling system
k Turn the battery disconnect switch to OFF 6. Remove band (7), and remove air cleaner
position, and remove the key. (For details, assembly (8). [*2]
see Testing and adjusting, "Handling battery
disconnect switch".)
Removal (WA470-A910-520-K-00-A)
Installation (WA470-A910-720-K-00-A)
50-136 WA470-7
50 Disassembly and assembly
Engine and cooling system
[*2]
a Install the clamp so that inlet (A) of air cleaner is
not caught by seal (9).
WA470-7 50-137
50 Disassembly and assembly
Engine and cooling system
Removal (WA470-AT50-520-K-00-A)
Installation (WA470-AT50-720-K-00-A)
50-138 WA470-7
50 Disassembly and assembly
Engine and cooling system
Removal (WA470-AKM4-520-K-00-A)
Installation (WA470-AKM4-720-K-00-A)
WA470-7 50-139
50 Disassembly and assembly
Engine and cooling system
k Turn the battery disconnect switch to OFF 4. Disconnect fuel hoses (4) and (5).
position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)
1. Drain fuel.
50-140 WA470-7
50 Disassembly and assembly
Engine and cooling system
WA470-7 50-141
50 Disassembly and assembly
Engine and cooling system
Installation (WA470-AD10-720-K-00-A)
50-142 WA470-7
50 Disassembly and assembly
Power train
Removal (WA470-R406-520-K-00-A)
6 Transmission case: 65 l
3. Remove full-length fender assembly. For details,
see "Removal and installation of full-length
fender assembly".
4. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood 11.Remove the cover on the right side of the
assembly". machine body and disconnect hose (6).
5. Remove the hydraulic tank assembly. For details, 12.Disconnect ground cable (6-1).
see "Removal and installation of hydraulic tank
assembly".
6. Remove the operator's cab and floor frame
assembly. For details, see "Removal and
installation of operator's cab and floor frame
assembly".
7. Remove all piping connected to the pump. For
details, see "Removal and installation of steering
lubrication pump and power train pump
assembly".
8. Remove all piping connected to the pump. For
details, see "Removal and installation of work
equipment pump and cooling fan pump
13.Remove tube (7). [*1]
assembly".
14.Remove the clamp (8), and move harnesses (9)
a Remove bracket (1). and (10).
WA470-7 50-143
50 Disassembly and assembly
Power train
50-144 WA470-7
50 Disassembly and assembly
Power train
WA470-7 50-145
50 Disassembly and assembly
Power train
Installation (WA470-R406-720-K-01-A)
50-146 WA470-7
50 Disassembly and assembly
Power train
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.
WA470-7 50-147
50 Disassembly and assembly
Power train
a Special tools
Necessity
Sym-
Q'ty
Necessity
Part No. Part name
bol
Sym-
Q'ty
Part No. Part name
bol
25 790-445-3810 Push tool t 1
793T-607-1550 Bracket t 1 26 790-201-2860 Spacer q 1
1 01051-62240 Bolt t 1 790-101-5401 Push tool kit q 1
01643-32260 Washer t 1 790-101-5421 • Grip 1
27
793T-607-1260 Plate t 1 790-101-5441 • Plate 1
01016-51645 Bolt t 1 01010-51240 • Bolt 1
2 28 790-434-1470 Push tool q 1
01016-51690 Bolt t 1
01010-81245 Bolt t 4 B 793T-607-1430 Push tool t 1
3 793T-607-1570 Plate t 1 29 790-101-5421 Grip t 1
4 790-102-1891 Nut wrench t 1 01010-51240 Bolt t 1
793T-607-1220 Lifting tool t 1 30 793T-607-1140 Spacer t 1
5 793T-607-1440 Push tool t 1
793-607-1230 Pin t 1
793T-607-1280 Lifting tool t 2 31 790-101-5421 Grip t 1
01016-31245 Bolt t 4 01010-51240 Bolt t 1
01580-11210 Nut t 4 32 793T-607-1450 Spacer t 1
01017-30250 Bolt t 2 Disassembly (WA470-CF00-530-K-00-A)
6
01643-32060 Washer t 4
a Be careful not to damage parts during
01580-12016 Nut t 4
disassembly (also during transporting and
793T-607-1290 Bar t 1
storing them).
04530-11628 Eyebolt t 1
If you damaged a part and the damage is
793T-607-1310 Plate t 1
repairable, repair it before assembly.
793T-607-1520 Push tool t 1
7 t If the damage is not repairable (when the repair
2989-01-1220 Bolt 1
can affect part's dimension, precision, surface
01643-33080 Washer t 1
roughness, etc.), replace the part with a new one.
B 01017-31420 Bolt t 8
t 1. Place the torque converter and transmission
793T-607-1330 Bracket 1
assembly on a level place, and stabilize it by
793T-607-1340 Plate t 1
8 using block, etc.
01010-80820 Bolt t 2 2. Remove steering pump and power train pump
01643-30823 Washer t 2 assembly (A).
793T-607-1350 Bolt t 1
9
04530-11018 Eyebolt t 1 4 Steering pump and power train pump
793T-607-1560 Sleeve t 1 assembly:
10 01017-51630 Bolt t 1 85 kg
01643-31645 Washer t 1
11 790-201-2660 Plate q 1
12 792-135-3360 Plate q 1
13 792-822-1430 Plate q 1
14 790-201-2860 Spacer q 1
15 792T-227-1110 Push tool t 1
16 792T-423-1320 Push tool t 1
17 790-201-2680 Plate q 1
18 794T-425-1110 Push tool t 1
19 793T-615-1810 Push tool t 1
20 791T-630-2410 Push tool t 1
21 790-201-2220 Plate q 1
22 790-201-2160 Plate q 1 3. Remove work equipment pump and cooling fan
23 793T-607-1420 Push tool t 1 pump assembly (B).
24 793T-623-1170 Push tool t 1
50-148 WA470-7
50 Disassembly and assembly
Power train
WA470-7 50-149
50 Disassembly and assembly
Power train
8) Remove torque converter outlet pressure 12)By using guide bolt [2], remove R ECMV
sensor (13) and torque converter oil assembly (20), 2nd ECMV assembly (21),
temperature sensor (13-1). 3rd ECMV assembly (22), block (23), and
9) Remove tube (14). filter (24) together with plate (25).
10)By using guide bolt [1], remove L/C ECMV 13)Remove transmission input shaft speed
assembly (15-1), F ECMV assembly (15), 1st sensor (26).
ECMV assembly (16), and 4th ECMV
assembly (17) together with plate (18).
50-150 WA470-7
50 Disassembly and assembly
Power train
WA470-7 50-151
50 Disassembly and assembly
Power train
50-152 WA470-7
50 Disassembly and assembly
Power train
12.Rear case
Remove outer races (50), (51), and (52) from the
rear case.
a When removing the bearing outer races from
3) By using tool B3, fix gear (43). the front case and the rear case, be careful
4) By using tool B4, remove nut (44).
not to damage the cases.
If any portion is scratched, modify it smoothly.
WA470-7 50-153
50 Disassembly and assembly
Power train
3) Remove gear (58). 2) By using tool B5, sling and remove F and 1st
clutch assembly (64).
50-154 WA470-7
50 Disassembly and assembly
Power train
WA470-7 50-155
50 Disassembly and assembly
Power train
50-156 WA470-7
50 Disassembly and assembly
Power train
WA470-7 50-157
50 Disassembly and assembly
Power train
17.Transfer gear 1
7) Tighten the outside bolts of tool B7 to a Transfer shaft 1 is removed together with the
separate and remove transfer shaft 2 (108) R and 2nd clutch pack assembly.
from transfer gear 2 (109). a When removing the bearing outer races from
a Tighten all the outside bolts evenly. the front case and the rear case, take
extreme care not to damage the cases.
2 Threaded portion and end face of
If any portion is scratched, modify it smoothly.
outside bolt:
1) Remove inner race (112) and bearing (113).
Molybdenum disulfide lubricant
8) Remove bearings (108a) and (108b) from a After removing bearing (113), remove the
transfer shaft 2 (108). remaining plate [a component part of
9) Move transfer gear 2 (109) sideways to bearing (113)].
remove.
10)Remove outer race (111) from front case
(110).
a When removing the bearing outer races
from the front case and the rear case,
take extreme care not to damage the
cases.
If any portion is scratched, modify it
smoothly.
50-158 WA470-7
50 Disassembly and assembly
Power train
19.Retainer
1) Remove retainer (121) from front case (117).
2) Remove dust seal (122) and oil seal (123)
from retainer (121).
18.Cage
1) Remove cage (118) and shim (119) from
front case (117).
Assembly (WA470-CF00-710-K-00-A)
WA470-7 50-159
50 Disassembly and assembly
Power train
2. Cage
1) By using tool B11, press fit outer race (120)
to cage (118).
2 Inner periphery of outer race:
Power train oil (TO10)
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50 Disassembly and assembly
Power train
WA470-7 50-161
50 Disassembly and assembly
Power train
5) Install tool B8 to transfer gear 2 (109). 11)Set heated transfer gear 2 (109) and tool B8
6) Heat transfer gear 2 (109) with tool B8 as a set in the front case (110).
installed in a heating cabinet.
k Do not hold transfer gear 2 (109) and
a Heat at temperature below 145°C for at
least 2 hours. tool B8 with bare hands.
2 Inner periphery of gear:
Power train oil (TO10)
12)Check that the inside faces of transfer gear 2
(109) and outer race (111) are aligned each
other.
13)Insert transfer shaft 2 (108) slowly into
transfer gear 2 (109).
a Insert the shaft until it stops.
a Once the shaft is positioned, do not raise
it. (At the moment when the shaft is
raised, the temperature difference
between the shaft and gear is lost and
7) Install tool B9 to transfer shaft 2 (108). they may be fixed together)
8) Refrigerate transfer shaft 2 (108) with tool B9 14)Check that level difference (b) between
installed in a freezer for at least 1 hour. transfer shaft 2 (108) and transfer gear 2
9) Refrigerate plate (107b) in the freezer. (109) is in the following range by using a
a The refrigerating time of the plate may be depth gauge.
shorter than that of transfer shaft 2 (108). • Dimension (b): -0.4 to 0.4 mm
10)Check that the temperature difference a If dimension (b) is out of the standard
between transfer gear 2 (109) and transfer value, separate the shaft and gear
shaft (108) is at least 140°C. immediately. Eliminate the cause, and
then repeat the procedure from step 6).
15)Leave the shaft and gear as they are for at
least 20 minutes until their temperature
decreases to the normal temperature.
16)Rotate transfer shaft 2 (108) to check that it
is press fitted to transfer gear 2 (109) (the
shaft and gear do not slip on each other).
a Do not raise transfer shaft 2 (108).
17)Remove tools B8 and B9.
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50 Disassembly and assembly
Power train
5. Parking brake
1) By using tools B17 and B18, press fit outer
race (104) to the front case.
2 Inner periphery of outer race:
Power train oil (TO10)
2) Install cover (103).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
WA470-7 50-163
50 Disassembly and assembly
Power train
2 Bearings (99) and (102): 6) Sling down and install housing (96).
Power train oil (TO10) 2 Periphery of O-ring:
Grease (G2-LI)
50-164 WA470-7
50 Disassembly and assembly
Power train
that the tightening torque of the mounting 5] to 7] until the value is in the preceding
bolt of retainer (93) has not changed. range.
a If the tightening torque has changed a If the shim thickness is increased by
0.98 Nm {0.1 kgm} or more, repeat 0.1 mm, the rotating torque changes
steps 1] and 2]. -5.88 to -1.96 Nm {-0.60 to -0.20
kgm}.
WA470-7 50-165
50 Disassembly and assembly
Power train
50-166 WA470-7
50 Disassembly and assembly
Power train
WA470-7 50-167
50 Disassembly and assembly
Power train
50-168 WA470-7
50 Disassembly and assembly
Power train
4) Install seal rings (61), (62), and (63) to each 3) Install gear (58).
clutch pack assembly.
a Check that the height difference between
a When installing seal rings (61) for the F the meshed 3 gears is 3 mm or less.
and 1st clutch pack and seal rings (63) for If the position of gear (140) is higher, F
the R and 2nd clutch pack, check that and 1st clutch pack assembly (64) may
there are oil grooves on their sides. be stopped at the faucet joint portion.
2 Periphery of seal ring:
Grease (G2-LI)
WA470-7 50-169
50 Disassembly and assembly
Power train
8. Rear case
By using tool B13, press fit outer races (50), (51),
and (52) to the rear case.
a Press fit bearing outer race (50) for the taper
roller bearing to the portion where there is
identification hole (a). 3) By using tool B25, press fit bearing (47) to
2 Inner periphery of outer race: gear (43).
Power train oil (TO10) 2 Bearing:
Power train oil (TO10)
4) Install cage (45) and bearing (46).
2 Bearing:
Power train oil (TO10)
5) Finger-tighten nut (44).
a Direct the chamfered side down.
6) Rotate gear (43) at least 10 turns to spread
oil.
9. PTO assembly
a Assemble the right and left PTO assemblies
in the same procedure.
a When installing inner race and outer race of
the bearing, check that their manufacturing
numbers and match symbols (A) or (B) are
the same.
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50 Disassembly and assembly
Power train
7) By using tool B3, fix gear (43). 2) By using tool B26, press fit cover (40) and
8) By using tool B4, tighten nut (44). tighten bolts (39) (10 pieces).
2 Nut: 2 Mounting bolt:
Adhesive (LT-2) Adhesive (LT-2)
3 Nut: 3 Mounting bolt:
392.3 to 441.3 Nm {40 to 45 kgm} 98 to 123 Nm {10 to 12.5 kgm}
WA470-7 50-171
50 Disassembly and assembly
Power train
50-172 WA470-7
50 Disassembly and assembly
Power train
2 Bearing:
Power train oil (TO10)
6) Remove cage (29).
WA470-7 50-173
50 Disassembly and assembly
Power train
50-174 WA470-7
50 Disassembly and assembly
Power train
WA470-7 50-175
50 Disassembly and assembly
Power train
3 Joint bolt
M8: 19.6 to 29.4 Nm {2.0 to 3.0
kgm}
M12: 34.3 to 44.1 Nm {3.5 to 4.5
kgm}
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50 Disassembly and assembly
Power train
14)Install tube (4) and gauge (5). 18.Install work equipment pump and cooling fan
pump assembly (B).
2 Gauge mounting bolt:
Adhesive (LT-2) 4 Work equipment pump and cooling
3 Gauge mounting bolt: fan pump assembly:
12.7 to 13.7 Nm {1.3 to 1.4 kgm} 160 kg
15)Install tube (3). 19.Install steering pump and power train pump
assembly (A).
3 Tube mounting joint:
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 4 Steering pump and power train pump
assembly:
85 kg
WA470-7 50-177
50 Disassembly and assembly
Power train
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
50-178 WA470-7
50 Disassembly and assembly
Power train
WA470-7 50-179
50 Disassembly and assembly
Power train
Assembly (WA470-CD00-710-K-00-A)
1. Complete turbine
5. Complete housing assembly Install turbine (27) to boss (25).
1) Remove the mounting bolts to separate
2 Mounting bolt:
complete housing (28) and case (29).
Adhesive (LT-2)
3 Mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
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50 Disassembly and assembly
Power train
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50 Disassembly and assembly
Power train
7. Pilot
Install pilot (22).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
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50 Disassembly and assembly
Power train
WA470-7 50-183
50 Disassembly and assembly
Power train
5) Install pump (7) and tighten bolts (6). 10.Stator assembly and turbine and case assembly
2 Mounting bolt: 1) Set stator assembly (13) to stator shaft (5).
2) Check that the stator rotates as follows when
Adhesive (LT-2)
seen from the boss side (input side: view A).
3 Mounting bolt: • Clockwise: Free rotation
58.8 to 73.5 Nm {6.0 to 7.5 kgm} • Counterclockwise: Locked
6) By using tool B34, tighten nut (4). 3) By using eyebolts [9] (M12 x 1.75), sling and
lower turbine and case assembly (40) and
a Install bolts (M12 x 1.75) (2 pieces) to the tighten bolts (2) lightly.
bottom of stator shaft (5) diagonally and 4) Turn over the torque converter assembly and
fix them by using bar [1]. tighten bolts (2).
2 Nut: 2 Bolt:
Adhesive (LT-2) Adhesive (LT-2)
3 Nut: 3 Bolt:
441 to 490 Nm {45 to 50 kgm} 49.0 to 58.8 Nm {5.0 to 6.0 kgm}
50-184 WA470-7
50 Disassembly and assembly
Power train
Necessity
Sym-
Q'ty
Part No. Part name
bol
Commercially Puller q 1
available or
Push puller t 1
43 790-101-2501
790-101-3201 Bearing puller t 1
790-201-1310 Plate t 1
Commercially
Puller q 1
44 available
790-201-1410 Plate t 1
790-101-2510 Block t 1 2. Spacer
790-101-2520 Screw t 1 1) Remove snap ring (2).
791-112-1180 Nut t 1
45
790-101-2540 Washer t 1
B 790-101-2450 Adapter t 1
790-201-2860 Spacer t 1
790-101-3501 Puller t 1
46
790-201-1320 Spacer t 1
47 793-415-1170 Seal holder t 1
48 793T-607-1420 Push tool q 1
49 793T-607-1370 Seal holder t 1
50 796T-467-2160 Push tool t 1
51 799-301-1500 Oil leak tester t 1
52 793T-607-1380 Seal holder t 1
53 792T-446-1150 Push tool t 1 2) By using tool B43, remove spacer (3).
54 793T-607-1390 Seal holder t 1
55 795-102-2730 Collar t 1
Disassembly (WA470-CF60-520-K-00-A)
[F clutch]
1. Bearing
WA470-7 50-185
50 Disassembly and assembly
Power train
4. End plate
1) Using vise [3], press end plate (8). 7. Piston
2) Remove snap ring (9). 1) By using bolts [4] (M8 x 1.25), remove piston
3) Remove end plate (8). (15).
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50 Disassembly and assembly
Power train
[1st clutch]
8. Bearing and 1st clutch gear
9. Washer
WA470-7 50-187
50 Disassembly and assembly
Power train
[R clutch]
11.Plate, disc, and spring 1. Bearing
Remove plate (28), disc (29), and spring (30). By using tool B43, remove bearing (34).
12.Piston 2. Spacer
1) By using bolts [7] (M8 x 1.25), remove piston 1) Remove snap ring (35).
(31).
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50 Disassembly and assembly
Power train
6. End plate
1) By using vise [10] and push tool [11], press
end plate (43).
2) Remove snap ring (44).
3) Remove end plate (43).
4. R clutch gear
1) Remove R clutch gear (39).
WA470-7 50-189
50 Disassembly and assembly
Power train
2) Remove snap ring (49) to remove lubricating 2) Remove inner race (54) from transfer shaft 1
piston (50) from piston (48). (53).
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50 Disassembly and assembly
Power train
11.End plate
1) Using tool B45, press end plate (59). 2) Remove seal rings (65) and (66) from piston
2) Remove snap ring (60). (64).
3) Remove end plate (59).
12.Plate, disc, and spring Assembly of 3rd and 4th clutch pack assembly
Remove plate (61), disc (62), and spring (63). [4th clutch]
1. Bearing
1) By using tool B43, remove bearing (67) and
plate (68).
2) Remove bearing (69).
WA470-7 50-191
50 Disassembly and assembly
Power train
4. End plate
1) Using vise [16], press end plate (75).
2) Remove snap ring (76).
3) Remove end plate (75).
3. Cylinder assembly
By using bolts (M8 x 1.25) remove cylinder
assembly (74).
7. Piston
1) By using bolts [17] (M8 x 1.25), remove
piston (83).
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50 Disassembly and assembly
Power train
[3rd clutch]
9. Bearing, spacer, and plate
1) Remove bearing (89).
a Stick tapes, etc. to bearing sliding surface
(a) of the shaft for protection.
2) Remove spacer (90).
8. 4th gear
1) Remove 4th gear (86).
10.3rd gear
1) Remove 3rd gear (95).
WA470-7 50-193
50 Disassembly and assembly
Power train
11.End plate
1) Using vise [18], press end plate (97). 2) Remove seal rings (103) and (104) from
2) Remove snap ring (98). piston (102).
3) Remove end plate (97).
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50 Disassembly and assembly
Power train
Assembly (WA470-CF60-720-K-00-A)
4. End plate
1) Using vise [18], press end plate (97).
2) Install snap ring (98).
a Check that the snap ring is fitted in the
2. Piston groove securely.
1) Install seal rings (103) and (104) to piston
(102) as shown in the figure. a Check that the end plate is returned to the
snap ring position.
WA470-7 50-195
50 Disassembly and assembly
Power train
5. 3rd gear
1) Install bearing (96) to 3rd gear (95).
7. Check of clearance
Move 3rd gear (95) up and down and check that
dimension (a) is in the standard value by using a
dial gauge.
• Dimension (a): 0.14 to 1.03 mm
2) Install spacers (92) and (91).
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50 Disassembly and assembly
Power train
11.End plate
1) Using vise [16], press end plate (75).
2) Install snap ring (76).
a Check that the snap ring is fitted in the
groove securely.
3) By using eyebolts [17] (M8 x 1.25), install
piston (83). a Check that the end plate is returned to the
snap ring position.
2 Seal ring contact surface:
Power train oil (TO10)
12.4th gear
Install 4th gear (86) to cylinder assembly (74).
9. Plate, bearing, and washer
Install washer (82), bearing (81), and plate (80).
a When installing plate (80), direct the
protruded side up.
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50 Disassembly and assembly
Power train
15.Bearing
1) By using tool B50, press fit bearing (69).
2 Both end faces of bearing:
Molybdenum disulfide lubricant or
molybdenum disulfide grease (LM-
G)
14.Ring, cover, and collar
1) Install seal rings (73) and collars (72).
2 Periphery of seal ring:
Grease (G2-LI)
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50 Disassembly and assembly
Power train
16.Check of clearance
Move 4th gear (86) up and down and check that
dimension (b) is in the standard value by using a
dial gauge.
• Dimension (b): 1.75 to 3.25 mm 3) By using bolts [15] (M8 x 1.25), install piston
(64).
2 Seal ring contact surface:
Power train oil (TO10)
3. End plate
Assembly of R and 2nd clutch pack assembly 1) Using tool B45, press end plate (59).
2) Install snap ring (60).
[2nd clutch]
a Check that the snap ring is fitted in the
1. Piston
groove securely.
1) Install seal rings (65) and (66) to piston (64)
as shown in the figure.
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50 Disassembly and assembly
Power train
6. Transfer shaft 1
1) By using tool B53, press fit inner race (54) to
4. Hub transfer shaft 1 (53).
Install hub (58).
[R clutch]
7. Piston
1) Install seal rings (51) and (52) to piston (48)
as shown in the figure.
2) By using tool B54, fit seal rings (51) and (52)
to piston (48).
a Leave it for 2 to 3 minutes as it is.
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50 Disassembly and assembly
Power train
9. End plate
1) By using vise [10] and push tool [11], press
end plate (43).
2) Install snap ring (44).
a Check that the snap ring is fitted in the
groove securely.
a Check that the end plate is returned to the
snap ring position.
WA470-7 50-201
50 Disassembly and assembly
Power train
13.Spacer
50-202 WA470-7
50 Disassembly and assembly
Power train
4. Washer
Install washer (25).
WA470-7 50-203
50 Disassembly and assembly
Power train
50-204 WA470-7
50 Disassembly and assembly
Power train
12.End plate
1) Using vise [3], press end plate (8).
2) Install snap ring (9).
5) By using bolts [4] (M8 x 1.25), install piston
(15). a Check that the snap ring is fitted in the
groove securely.
2 Seal ring contact surface:
Power train oil (TO10) a Check that the end plate is returned to the
snap ring position.
WA470-7 50-205
50 Disassembly and assembly
Power train
15.Spacer
1) By using tool B50, press fit spacer (3).
14.Bearing
Install bearing (4).
17.Check of clearance
Move F clutch gear (5) up and down and check
that dimension (e) is in the standard value by
using a dial gauge.
• Dimension (e): 0.28 to 0.95 mm
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50 Disassembly and assembly
Power train
WA470-7 50-207
50 Disassembly and assembly
Power train
k Place the machine on a level ground, and 4 Front tire and rim assembly:
turn the parking brake switch to ON position.
700 kg
k Set the frame lock bar to LOCK position, and
chock the wheels.
Removal (WA470-DA20-520-K-00-A)
50-208 WA470-7
50 Disassembly and assembly
Power train
Installation (WA470-DA20-720-K-00-A)
WA470-7 50-209
50 Disassembly and assembly
Power train
k Place the machine on a level ground, and 6. Set jack [3] under the counterweight to support
turn the parking brake switch to ON position. the rear frame end.
50-210 WA470-7
50 Disassembly and assembly
Power train
12.Disconnect clamps (6) (2 places). 16.Disconnect rear drive shaft (12). [*2]
a Another is in the upper part of the figure. a Make matchmarks on the coupling and drive
shaft, and then remove them.
WA470-7 50-211
50 Disassembly and assembly
Power train
50-212 WA470-7
50 Disassembly and assembly
Power train
Installation (WA470-DAC0-720-K-00-A)
WA470-7 50-213
50 Disassembly and assembly
Power train
• Air bleeding
Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from wheel
brake circuit".
[*7]
2 Thrust cap mounting bolt:
Adhesive (LT-2)
3 Thrust cap mounting bolt:
245 to 308 Nm {25 to 31.5 kgm}
[*8]
2 Thrust plate mounting bolt:
Adhesive (LT-2)
3 Thrust plate mounting bolt:
245 to 308 Nm {25 to 31.5 kgm}
[*9]
a Securely install packing (25) to the groove with
its lip facing to the axle housing side.
a Install bush (26) with chamfer (a) facing to the
axle housing side so that clearance (b) is in the
dimension as follows.
• Clearance (d): 0.5 mm
2 Contacting surface of support bushing:
Grease (G2-LI)
50-214 WA470-7
50 Disassembly and assembly
Power train
a Special tools
Necessity
Q'ty
Symbol Part No. Part name
Commercially
1 Puller q 1
D16 available
2 790-201-1410 Plate t 1
1 793T-622-2520 Block t
2 790-101-2520 Screw t 1
3 791-112-1180 Nut t 1
4 790-101-2540 Washer t 1
Leg 2. Axle assembly
5 790-101-2620 t 2
Place the axle assembly on blocks [1].
D17 6 790-101-2570 Plate t 4
7 790-101-2560 Nut t 2 a Set blocks [1] so that the assembly does not
8 790-101-2740 Adapter t 2 lean when one axle housing assembly is
9 790-201-1410 Plate t 1 removed.
10 790-101-2102 Puller assembly t 1
11 790-101-1102 Hydraulic pump t 1
1 790-101-2800 Bearing puller t 1
D18 2 793T-622-2530 Bolt t 2
3 01643-32060 Washer t 2
D19 793T-622-2540 Spacer q 1
D20 793T-622-2550 Spacer q 1
1 793T-622-1330 Push tool t 1
D21
2 793T-622-1340 Spacer t 1
1 793T-622-1370 Support t 2
D22
2 01010-50830 Bolt t 6
D23 793T-622-2510 Spacer t 1 3. Axle housing assembly
D24 793T-622-1510 Holder t 1
1) Sling axle housing assembly (8), and remove
D25 79A-264-0021 Push-pull scale q 1
the housing mounting bolts.
a The following photos and illustrations show the a When removing both right and left axle
front axle housing as an example. housing assemblies, put a match mark on
a The front and rear axle housings have different each housing and the differential case to
appearance but have the same internal prevent confusion.
structure. 2) Remove axle housing assembly (8).
Disassembly (WA470-DA04-520-K-00-A)
4 Axle housing assembly:
1. Draining oil 280 kg
Remove oil plug (1) to drain oil.
6 Axle oil
Front axle: 57l
l
Rear axle: 56l
l
WA470-7 50-215
50 Disassembly and assembly
Power train
5. Ring gear
By using tool D16, pull up ring gear (12) evenly
to remove it from axle housing assembly (13).
4. Planetary carrier assembly:
1) Remove axle shaft mounting bolt (9), and a Install a plate to the bolt end at the center of
sling and remove planetary carrier assembly tool D16 to adjust the height of the bolt.
(10). a Be careful that the hooks of tool D16 do not
a Be careful not to damage washer (9a). come off the ring gear.
6. Axle shaft
1) Set axle housing (14) so that it does not fall
down.
2) By using tool D17, push down axle shaft (15),
and separate it from bearing (26).
3) Sling axle housing (14).
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50 Disassembly and assembly
Power train
8. Axle housing
Remove outer races (18) and (19) from axle
housing (14).
WA470-7 50-217
50 Disassembly and assembly
Power train
Assembly (WA470-DA04-720-K-00-A)
1. Axle housing
1) By using tool D19, press fit outer race (18) to
axle housing (14).
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50 Disassembly and assembly
Power train
WA470-7 50-219
50 Disassembly and assembly
Power train
50-220 WA470-7
50 Disassembly and assembly
Power train
5. Planetary carrier
1) Install bearing (25) to planetary gear (23).
WA470-7 50-221
50 Disassembly and assembly
Power train
50-222 WA470-7
50 Disassembly and assembly
Power train
4) Rotate axle housing (14) to fit the bearings 3) Install guide bolt [5].
thoroughly. 4) Sling axle assembly (8) horizontally and
5) Install tool D25 to hole (h) of axle housing install it slowly, while aligning it with the
(14) to measure the starting torque. spline groove and guide bolts [5].
• Starting torque a Be careful not to damage the brake piston
Front axle: surface and plate surface when installing
30.4 to 115.6 N {3.1 to 11.8 kg} the assembly.
Rear axle: 5) Tighten the mounting bolts in diagonal order.
28.4 to 129.3 N {2.9 to 13.2 kg}
3 Housing mounting bolt:
a If the starting torque is out of the standard
490 to 608 Nm {50 to 62 kgm}
value, perform adjustment again from
Step 4.-6).
6) Install dial gauge [4] to axle housing (14) and
check that the planetary carrier has no end
play in its end face.
5 Axle oil
Front axle: 57 l
Rear axle: 56 l
WA470-7 50-223
50 Disassembly and assembly
Power train
50-224 WA470-7
50 Disassembly and assembly
Power train
Necessity
2) Disconnect connector (4) and remove oil
Q'ty
Symbol Part No. Part name temperature sensor (5).
3. Rear support (rear differential)
Unit repair stand Remove rear support (6). For details, see
1 790-501-5000 q 1
"Removal and installation of rear axle assembly".
D1 2 790-901-2110 Bracket q 1
3 790T-901-3440 Plate q 1
D2 793T-622-2570 Eyebolt t 2
D3 790-201-2730 Spacer q 1
1 793T-615-1730 Spacer (F) q 1
D4
2 790-201-2770 Spacer (R) q 1
1 790-201-2780 Spacer (F) q 1
D5
2 793T-623-1210 Spacer (R) q 1
1 796-765-1110 Push tool t 1
D6
2 790-201-2750 Spacer t 1
1 796-765-1110 Push tool (F) t 1
D7
2 792T-413-1120 Push tool (R) t 1
D8 79A-264-0021 Push-pull scale q 1
1 793T-622-1310 Push tool t 1
D9 2 790-101-5421 Grip t 1
3 01010-51240 Bolt t 1
1 793T-622-1310 Push tool t 1
2 793T-622-1320 Spacer t 1
D10
3 790-101-5421 Grip t 1
4 01010-51240 Bolt t 1
D11 793T-622-1360 Push tool t 1
1 793T-622-2560 Wrench t 1
D12
2 01316-10616 Bolt t 2
D13 793T-615-1730 Spacer q 1
799-101-5230 Adapter t 1 4. Axle housing assembly
1
07002-11423 O-ring t 1 Remove the right and left axle housing
D14 assemblies. For details, see "Disassembly and
2 793-605-1001 Brake tester t 1
3 790-101-1102 Hydraulic pump t 1 assembly of axle housing assembly".
D15 799-301-1500 Oil leak tester kit t 1 5. Differential assembly
D25 79A-264-0021 Push - pull scale q 1 Place differential assembly (7) on blocks [1] and
stabilize it. (Or install it to tool D1.)
• (F): For front differential
• (R): For rear differential a When using tool D1, remove the cage
assembly referring to Step 8.
Disassembly (WA470-DC10-520-K-00-A) 6. Cover
a Photos and illustrations, except those which Remove cover (8).
indicate the component name, show the front
differential.
a The front and rear differentials have different
external appearance and shape but have the
same internal structure.
1. Brake piping
1) Remove tube (1).
2) Remove slack adjuster (2). (Front differential)
a The slack adjuster of the rear differential
is installed to the rear frame.
WA470-7 50-225
50 Disassembly and assembly
Power train
7. Brake
8. Cage assembly
1) Remove sun gear shaft (9).
1) Sling the differential case, and set it with
2) Remove bolts (10) and remove outer plate
cage assembly (20) up.
(11).
2) Remove mounting bolts (21).
3) Remove plates (12), wave springs (13) and
discs (14). a Put a match mark on the cage and
differential case for assembly purpose.
a Put a mark on them to avoid confusion
3) Tighten the forcing screws to raise cage
between the right and left side parts.
assembly (20) until you can see the O-ring.
4 Cage assembly:
60 kg
50-226 WA470-7
50 Disassembly and assembly
Power train
9. Bearing carrier
1) Set the differential case so that the mounting
face of the cover removed in step 6 is up.
2) Sling differential carrier assembly (23).
a The figure shows the limited slip
differential specification.)
10.Differential carrier assembly
1) Remove differential carrier assembly (23)
from differential case (25).
a Be careful that the sling does not come
off.
WA470-7 50-227
50 Disassembly and assembly
Power train
50-228 WA470-7
50 Disassembly and assembly
Power train
7) Remove bevel gear (73) and bearing (74) 2) Remove bearing (27) from cover (28).
from case (72).
WA470-7 50-229
50 Disassembly and assembly
Power train
50-230 WA470-7
50 Disassembly and assembly
Power train
Assembly (WA470-DC10-720-K-00-A)
WA470-7 50-231
50 Disassembly and assembly
Power train
50-232 WA470-7
50 Disassembly and assembly
Power train
2 Bolt (17):
Adhesive (LT-2)
3 Bolt (17):
824 to 1,030 Nm {84 to 105 kgm}
2) Install plug (17b).
WA470-7 50-233
50 Disassembly and assembly
Power train
50-234 WA470-7
50 Disassembly and assembly
Power train
WA470-7 50-235
50 Disassembly and assembly
Power train
50-236 WA470-7
50 Disassembly and assembly
Power train
4) Install bushing (69), pinion gear (67), and 8) Install case (62).
spherical washer (68) to spider shaft (66).
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
WA470-7 50-237
50 Disassembly and assembly
Power train
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
50-238 WA470-7
50 Disassembly and assembly
Power train
2) Install guide bolts [6] to differential case (25). 2) If the backlash is out of the standard value,
3) Install standard shims (22) (of the quantity adjust the shims according to the following
and thickness checked during disassembly). procedure.
a Set the thinner shims on the cage side. a Moving of shims must not vary the sum of
thicknesses of the right and left shims.
a Determine the final quantity and
thickness of the shims after adjusting the a If the backlash is over the standard value,
backlash in step 8 and checking the move a part of shims (a) to shims (b).
contacts in step 9.
a If the backlash is below the standard
4) By using tool D2, install cage assembly (20).
value, move a part of shims (b) to shims
3 Mounting bolt: (a).
245 to 309 Nm {25 to 31.5 kgm}
WA470-7 50-239
50 Disassembly and assembly
Power train
10.Adjusting tooth contact When the pinion gear is too close to the bevel
If no correct tooth contact pattern is found in the gear
testing, adjust it according to the following
a Tooth contact pattern is as shown in the
procedure.
figure.
a Adjustment is done by increasing or 1) Increase shims (d) to move the pinion gear in
decreasing shims (a) and (b) (to move the direction (E).
bevel gear) and increasing or decreasing 2) Adjust shims (a) and (b) to move the bevel
shims (d) (to move the pinion gear). gear in direction (F).
a In order not to change the preload of the
bearing, do not change the total thickness of
shims (a) and (b).
a After adjusting tooth contact, check the
backlash again.
50-240 WA470-7
50 Disassembly and assembly
Power train
When the bevel gear is too far from the pinion a Leave the pressure at 4.9 MPa {50 kg/
gear cm2} for 5 minutes and check that
pressure drop is 0.1 MPa {1.0 kg/cm2} or
a Tooth contact pattern is as shown in the
less.
figure.
1) Increase shims (d) to move the pinion gear in a If oil leakage is detected, remove the
direction (E). brake piston and check the O-ring and
2) Adjust shims (a) and (b) to move the bevel seal for any damage. Then install them
gear in direction (F). again.
11.Brake
1) Install the seal to piston (16), and install the
piston to the differential and carrier
assembly.
a (15) is the brake oil port.
2 Seal:
Grease (G2-LI)
WA470-7 50-241
50 Disassembly and assembly
Power train
• Front differential
13.Axle housing
Install the right and left axle housing assemblies.
For details, see "Disassembly and assembly of
axle housing assembly".
14.Rear support (rear differential)
12.Cover Install rear support (6). For details, see
Install cover (7) to differential case (8). "Removal and installation of rear axle assembly".
a Apply liquid gasket (A) without a break. 15.Oil temperature sensor (rear differential)
1) Install oil temperature sensor (5) and connect
a Apply liquid gasket (A) at the center of
connector (4).
mating surface in the drawing.
2 Threaded portion of oil
2 Cover mounting surface:
temperature sensor:
Liquid gasket (Locktite 515)
Liquid gasket (LG-5)
3 Mounting bolt:
3 Oil temperature sensor:
157 to 196 Nm {16 to 20 kgm}
29.4 to 49.0 Nm {3 to 5 kgm}
50-242 WA470-7
50 Disassembly and assembly
Power train
17.Refilling of oil
1) Tighten drain plug (1-2) and add oil to the
specified level through the oil filler port.
5 Axle oil
Front axle: 57 l
Rear axle: 56 l
WA470-7 50-243
50 Disassembly and assembly
Steering system
50-244 WA470-7
50 Disassembly and assembly
Steering system
Installation (WA470-F570-720-K-00-A)
WA470-7 50-245
50 Disassembly and assembly
Brake system
Removal (WA470-G2H0-520-K-00-A)
Installation (WA470-G2H0-720-K-00-A)
50-246 WA470-7
50 Disassembly and assembly
Brake system
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
793T-607-1550 Bracket t 1
B 1 01051-62240 Bolt t 1
01643-32260 Washer t 1
k Set the frame lock bar to LOCK position, and 6. Remove mounting bolts (6) (2 pieces), and
chock the wheels. tighten them alternately into plug mounting part
(a). [*4]
k Lower the work equipment to the ground,
and set the work equipment lock switch to a Remove bolts (6) (2 pieces) on the diagonal
LOCK. positions.
a Piston (7) is pulled back by tightening bolts
k Turn the starting switch to OFF position, and (6), then the parking brake is released.
stop the engine.
a Tighten the bolts (2 pieces) gradually and
k Turn the battery disconnect switch to OFF evenly.
position, and remove the key. (For details, (Tighten the bolts approximately three turns
see Testing and adjusting, "Handling of after it contacts the seat surface.)
battery disconnect switch".) 7. Remove remaining bolts (6) (2 pieces). [*4]
8. Among 12 bolts (8), remove all the bolts other
Removal (WA470-GJ72-520-K-00-A) than 2 bolts diagonally installed. [*5]
1. Drain oil from the transmission case.
6 Transmission case: 65 l
2. Remove oil filler pipe (1).
3. Remove guard (2) and disconnect center drive
shaft (3) from the transmission.
a Retract the center drive shaft. [*1]
4. Remove coupling (4). [*2]
5. Remove plug (5). [*3]
WA470-7 50-247
50 Disassembly and assembly
Brake system
50-248 WA470-7
50 Disassembly and assembly
Brake system
Refilling of oil
• Refill with oil to the specified level through the oil
filler port. Run the engine to circulate the oil
through the system. Then check the oil level
again.
5 Transmission case: 65 l
WA470-7 50-249
50 Disassembly and assembly
Undercarriage and frame
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
Removal (WA470-H1L2-520-K-00-A)
50-250 WA470-7
50 Disassembly and assembly
Undercarriage and frame
8. Disconnect connectors FR1 (3), FR2 (4), FR3 15.Disconnect hoses (17) to (20) on the front frame
(5), and FR4 (6). side.
9. Disconnect hose (7). 16.Disconnect hose (21) on the front frame side.
10.Disconnect hoses (8) and (9). 17.Disconnect hoses (22) and (23) from steering
11.Remove clamp (8a). valve (24).
12.Disconnect hoses (10) to (13). 18.Remove lock bolt (25a) and pull out lower hinge
13.Remove clamps (14a) and (15a). pin (25). [*3]
14.Disconnect hoses (14) to (16).
WA470-7 50-251
50 Disassembly and assembly
Undercarriage and frame
19.Remove bolts (26) (4 pieces) and spacer (27). a Check that all pipings and harnesses are
[*4] disconnected.
20.Remove bolts (28) (6 pieces) and remove
a Be careful that the lower spacer of the upper
retainer (29). [*5]
hinge is not caught in the rear frame.
a Record the number and thickness of the
a Slide the crane forward while slinging the
shims between the retainer and frame.
front frame.
50-252 WA470-7
50 Disassembly and assembly
Undercarriage and frame
28.Remove bushings (41) on the top and bottom 31.Remove dust seal (44) from the lower hinge of
from the lower hinge of rear frame (34). [*12] front frame (33), and remove bearing (45). [*15]
29.Remove the mounting bolt from the lower hinge Installation (WA470-H1L2-720-K-00-A)
of front frame (33), and remove retainer (42).
[*13] • Perform installation in the reverse order of
removal.
a Record the number and thickness of the [*1]
shims between the retainer and frame.
3 Drive shaft mounting bolts:
98 to 123 Nm {10 to 12.5 kgm}
[*2]
a Adjust clearance (a) and (b) of the mounting
surfaces of the cylinder and frame to the
specified value by using shims.
• Clearance (a) and (b): Max. 0.5 mm
a Be sure to provide clearance.
WA470-7 50-253
50 Disassembly and assembly
Undercarriage and frame
a Assemble the upper hinge pin according to the between retainer and hinge to the specified
following procedure. value.
1. Install tools E1 to E8 to top of the upper hinge • Clearance (d): Max. 0.1 mm (average)
pin of front frame (33), set bearing (40) on tool
3 Mounting bolt:
E1, and install it from upper side to press-fit
portion to press-fit. 20 ± 2 Nm {2 ± 0.2 kgm}
4. After adjustment using shims, tighten every
a When press-fitting it, use tool E4 as a guide. retainer mounting bolt to the specified torque.
a Be careful that the bearing does not tilt. 2 Mounting bolt:
a When replacing bearing (40), replace it as a Liquid adhesive (Loctite LT-2)
set with spacers (32) and (38).
3 Mounting bolt:
a For spacers (32) and (38), see steps 22 and 98 to 123 Nm {10 to 12.5 kgm}
26.
2 Inner portion of bearing: Grease (G2-
LI)
50-254 WA470-7
50 Disassembly and assembly
Undercarriage and frame
[*12], [*13], [*14], [*15] 3. Lightly tighten retainer (42) evenly using 3
mounting bolts. Select shims to adjust clearance
a Install the lower hinge according to the following
(e) between retainer and hinge to the specified
procedure.
value.
1. Press fit bearing (45) to front frame (33) with
• Clearance (e): Max. 0.1 mm (average)
tools E1 to E8.
3 Mounting bolt:
a When press-fitting it, use tool E1 as a guide.
20 ± 2 Nm {2.0 ± 0.2 kgm}
a Be careful that the bearing does not tilt. 4. After adjustment using shims, tighten every
2 Inner portion of bearing: retainer mounting bolt to the specified torque.
Grease (G2-L1) 2 Mounting bolt:
Liquid adhesive (Loctite LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
WA470-7 50-255
50 Disassembly and assembly
Undercarriage and frame
50-256 WA470-7
50 Disassembly and assembly
Undercarriage and frame
WA470-7 50-257
50 Disassembly and assembly
Undercarriage and frame
k Turn the battery disconnect switch to OFF 4. Disconnect connector R20 (10) on the left inside
position, and remove the key. (For details, the rear frame.
see Testing and adjusting, "Handling of a Remove the harness clamp and pull out the
battery disconnect switch".) harness toward outside the machine body.
Removal (WA470-H700-520-K-00-A)
50-258 WA470-7
50 Disassembly and assembly
Undercarriage and frame
Installation (WA470-H700-720-K-00-A)
WA470-7 50-259
50 Disassembly and assembly
Undercarriage and frame
Removal (WA470-H560-520-K-00-A)
Installation (WA380-H560-720-K-00-A)
50-260 WA470-7
50 Disassembly and assembly
Hydraulic system
k Turn the battery disconnect switch to OFF 6. Disconnect hoses (3) to (6).
position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)
Removal (WA470-PM30-520-K-00-A)
WA470-7 50-261
50 Disassembly and assembly
Hydraulic system
4 Bracket (16): 30 kg
50-262 WA470-7
50 Disassembly and assembly
Hydraulic system
Installation (WA470-PM30-720-K-00-A)
WA470-7 50-263
50 Disassembly and assembly
Hydraulic system
Removal (WA470-R404-520-K-00-A)
50-264 WA470-7
50 Disassembly and assembly
Hydraulic system
WA470-7 50-265
50 Disassembly and assembly
Hydraulic system
Installation (WA470-R404-720-K-00-A)
50-266 WA470-7
50 Disassembly and assembly
Hydraulic system
Removal (WA470-C200-520-K-01-A)
WA470-7 50-267
50 Disassembly and assembly
Hydraulic system
Installation (WA470-C200-720-K-01-A)
50-268 WA470-7
50 Disassembly and assembly
Hydraulic system
Removal and installation of work equipment pump and cooling fan pump
assembly (WA470-C200-924-K-00-A)
k Place the machine on a level ground, and 10.Remove clamp (9).
turn the parking brake switch to ON position.
WA470-7 50-269
50 Disassembly and assembly
Hydraulic system
50-270 WA470-7
50 Disassembly and assembly
Hydraulic system
Necessity
and remove them.
Sym-
Q'ty
Part No. Part name
bol a When the piston rod assembly is pulled
out of the cylinder, oil flows out. So
1 790-502-1003 Cylinder repair stand t 1 prepare a container to receive the oil.
F1
2 790-101-1102 Hydraulic pump t 1
Socket (width across
F2 90-302-1280 flats: 55 mm) t 1
1 790-330-1100 Wrench assembly t 1
F3
2 790-102-2304 Wrench assembly t 1
1 790-102-4300 Wrench assembly t 1
F4
2 790-102-4310 Pin t 1
1 790-720-1000 Expander t 1
2 796-720-1650 Ring (*1) t 1
F5 3 07281-01029 Clamp (*1) t 1
4 796-720-1680 Ring (*2) t 1
5 07281-01589 Clamp (*2) t 1
1 790-201-1500 Push tool kit t 1 4) Set cylinder head and piston rod assembly
2 790-101-5021 • Grip 1 (3) on tool F1.
3 01010-50816 • Bolt 1 5) By using tool F2, remove nut (5).
F6
4 790-201-1570 • Plate 1 a Width across flats of nut: 55 mm
5 790-201-1990 Plate t 1 6) Remove piston (6) and remove cylinder head
6 790-201-1660 • Plate 1 (2).
1 790-201-1702 Push tool kit t 1
2 790-101-5021 • Grip 1
3 01010-50816 • Bolt 1
F7
4 790-201-1761 • Push tool 1
5 790-201-1930 • Push tool 1
6 790-201-1851 • Push tool 1
*1: For steering cylinder
*2: For lift cylinder and bucket cylinder
Disassembly (WA470-PPZ0-520-K-00-A)
WA470-7 50-271
50 Disassembly and assembly
Hydraulic system
50-272 WA470-7
50 Disassembly and assembly
Hydraulic system
Assembly (WA470-PPZ0-720-K-00-A)
WA470-7 50-273
50 Disassembly and assembly
Hydraulic system
50-274 WA470-7
50 Disassembly and assembly
Hydraulic system
WA470-7 50-275
50 Disassembly and assembly
Hydraulic system
50-276 WA470-7
50 Disassembly and assembly
Hydraulic system
WA470-7 50-277
50 Disassembly and assembly
Work equipment
k Turn the battery disconnect switch to OFF 5. Sling bucket cylinder (3).
position, and remove the key. (For details, 6. Remove pin (4) to separate the cylinder rod from
see Testing and adjusting, "Handling of the bell crank. [*3]
battery disconnect switch".)
4 Bucket cylinder (3): 210 kg
Removal (WA470-L100-520-K-00-A)
50-278 WA470-7
50 Disassembly and assembly
Work equipment
15.Sling bucket link (11) and pull out pin (12) and
remove it.
4 Bucket link: 90 kg
11.Disconnect connector F11 (7b).
12.Remove bolts (2 pieces) and remove boom
angle sensor assembly (7). [*5]
WA470-7 50-279
50 Disassembly and assembly
Work equipment
19.Sling bell crank (13) and pull out pin (14) and
remove it. [*8] 22.Remove dust seal (20) and bushing (21) from
bucket linkage (11). [*9]
4 Bell crank angle: 390 kg
20.Remove dust seal (16) and bushing (17) from Installation (WA470-L100-720-K-00-A)
[*1]
a Install the bucket link according to the following
procedure.
50-280 WA470-7
50 Disassembly and assembly
Work equipment
1. Sling bucket link (11) and install O-ring (22). k When aligning mounting holes for the pin,
2. Align the pin hole positions of bucket (23) and never insert your fingers in the holes.
bucket link (11).
[*5]
k Do not insert your finger to the pin hole. For checking operation after adjustment of
installation position, see Testing and Adjusting,
a Be careful that the O-ring does not get
"Testing and adjusting boom position detection
caught.
lever".
3. Insert the shim so that clearance (a) is even on
right and left sides. Install pin (1) and lock it with [*6]
the bolt. a Install the boom, bell crank and bucket linkage
• Clearance (a): Max. 1.5 mm assembly according to the following procedure.
• Set shim thickness: 1.5 mm, 3.0 mm 1. Sling boom, bell crank and bucket linkage
assembly to align the pin hole positions of front
frame (25) and lift arm (15).
WA470-7 50-281
50 Disassembly and assembly
Work equipment
a Install the dust seal with its lip (a) facing outside.
a The following figure shows the boom (bucket
side).
• Greasing
Grease each pin after installation is completed.
2 Pins:
Molybdenum disulfide grease (LM-G)
50-282 WA470-7
50 Disassembly and assembly
Cab and its attachments
Removal (WA470-K000-520-K-00-A)
WA470-7 50-283
50 Disassembly and assembly
Cab and its attachments
50-284 WA470-7
50 Disassembly and assembly
Cab and its attachments
17.Remove air conditioner hoses (22) and (23), and 20.Remove the monitor controller assembly. For
remove heater hoses (24) and (25). [*3] details, see "Removal and installation of monitor
controller assembly."
21.Remove mounting bolts (27) of operator's cab
and floor frame assembly.
WA470-7 50-285
50 Disassembly and assembly
Cab and its attachments
50-286 WA470-7
50 Disassembly and assembly
Cab and its attachments
New/Redesign
pliers [3]. In this case, clip both ends of wire
Necessity
Quantity
with pliers (or wind wire around pliers) and
Sketch
Symbol Part No. Part name insert wire to the position where adhesive
stays to cut it off.
k Lower the work equipment to the ground. a When you use a seal cutter or ultrafine wire,
take care not to damage parts in the
k Stop the engine, turn the battery disconnect operator's cab (such as resin covers).
switch to the OFF position, and remove the
key. a When removing shattered window glass, it is
allowed to use cutter knife [4] and a
a Place the machine at the place where it is not screwdriver. (Applying a screwdriver directly
wet or windy. Open the door either on right or left. to an unbroken window glass most possibly
Do not close the door until cure of the glass ends up breaking the glass.)
replacement is finished. a When using a cutter knife [4], insert a flat
(Because the glass may be dropped by head screwdriver to the cutting edge to cut
increasing of internal pressure inside the cab if through while widening the cutting edge.
the door is opened or closed.)
Removal (WA380-K183-520-K-00-A)
WA470-7 50-287
50 Disassembly and assembly
Cab and its attachments
50-288 WA470-7
50 Disassembly and assembly
Cab and its attachments
a For the right and left windows and rear and fit the window glass to the operator's
window, dam rubber is attached all around cab.
them. Start bonding of dam rubber from the
upper center position of the window and,
after bonding it almost around the window,
stop at a point about 5 mm away from
starting point "c" to leave the clearance.
6. Apply primer.
a Since useful life of primer (5) is four months
from the date of production, be sure not to
use an overdue primer.
a Make sure to use primer within two hours
from opening its cap.
a Even when it is plugged again immediately
after opening, be sure to use it within 24
hours from opening.
(A primer must be disposed when 24 hours have
elapsed from opening.)
1) Agitate both primers for paint surface and
3) By using tool X3 (suction cup), place window glass sufficiently before use.
glass (3) on tool X2-1 (5 mm thick spacer)
WA470-7 50-289
50 Disassembly and assembly
Cab and its attachments