The Komatsu WA320-7 Wheel Loader is a mid-size loader used for quarry work, snow, feedlots, and general construction loading. People who reach for the Komatsu WA320-7 Wheel Loader Shop Manual (SEN06202-17) are usually field techs or shop mechanics who actually have to tear into these machines, not just grease them. They’re trying to track down electrical gremlins, hydraulic issues, driveline problems, or rebuild major components the right way the first time.
What this manual helps you do
- Trace hydraulic faults in the loader’s working circuits and steering by following factory-style diagrams and step sequences.
- Diagnose engine, transmission, and brake issues using the kind of test procedures and checks you’d expect in a shop manual.
- Follow disassembly and reassembly procedures for major components so you don’t guess at order, orientation, or special tools.
- Check wiring, sensors, and control units with schematic-style information that lets you chase intermittent electrical faults.
- Verify adjustment points and re-check systems after repair so the machine goes back to work without comeback failures.
Who this is for
This is aimed at shop mechanics, dealer or independent field techs, and fleet maintenance people who actually perform repairs on a WA320-7. If you just operate the loader or only need daily service intervals and basic checks, you’re really after the Operation & Maintenance Manual, not this one.
FAQ
Q: Is this a PDF I can search and print?
A: Yes, it’s a PDF, so you can search by keyword and print specific pages for use in the shop.
Q: Is this deep enough for full overhauls and serious troubleshooting?
A: This kind of shop manual usually covers workshop-level diagnostics, teardown, inspection, and reassembly for the WA320-7 systems.
Q: How do I know if it matches my exact machine variant?
A: You’ll want to match your machine’s identification plate and serial information with the SEN06202-17 reference before relying on it.
Bottom line: If you’re the one actually fixing a Komatsu WA320-7, this shop manual is what you want; if you just need basic operation or fluid intervals, keep looking for the O&M book instead.
📘 Show Index
Table of Contents:
- 00 Index and foreword
- Index
- Foreword, safety and general information
- Important safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling equipment of fuel system devices
- Handling of intake system parts
- Handling of hydraulic equipment
- Method of disconnecting and connecting of push-pull type coupler
- Handling of electrical equipment
- How to read electric wire code
- Precautions when performing operation
- Practical use of KOMTRAX
- Standard tightening torque table
- List of abbreviation
- Conversion table
- 01 Specification
- Table of contents
- Specifications
- Specification drawing
- Specifications
- Weight table
- Table of fuel, coolant, and lubricants
- 10 Structure and function
- Table of contents
- Engine and cooling system
- Engine related parts
- KVGT
- EGR system piping drawing
- EGR system circuit diagram
- EGR valve
- EGR cooler
- KCCV layout drawing
- KCCV ventilator
- KDPF
- Cooling system
- Cooling fan motor
- Power train
- Power train system
- Layout of power train parts
- Damper
- HST pump
- HST motor1
- HST motor2
- Transfer
- Clutch solenoid valve
- Drive shaft
- Axle
- Differential
- Torque proportional differential
- Limited slip differential
- Final drive
- Steering system
- Layout of steering devices
- Steering column
- Priority valve
- Cushion valve
- Emergency steering valve
- Orbitrol valve
- Brake system
- Layout of brake parts
- Brake accumulator charge valve
- Brake valve
- Brake accumulator
- Slack adjuster
- Brake
- Parking brake control
- Parking brake
- Parking brake solenoid valve
- Undercarriage and frame
- Axle mount
- Center hinge pin
- Tire
- Hydraulic system
- Hydraulic component layout
- Work equipment control
- Hydraulic tank
- Double type gear pump
- Steering and work equipment pump
- Control valve
- CLSS
- Hydraulic circuit diagram and names of valves
- Self-pressure reducing valve
- Work equipment PPC valve
- Work equipment lock solenoid valve
- PPC circuit accumulator
- ECSS accumulator
- Work equipment
- Work equipment linkage
- Bucket
- Cab and its attachments
- Electrical system
- Engine control system
- Preheating system
- Engine output limit function
- Automatic warm-up function
- Parking brake control system
- System operating lamp function
- Battery disconnect switch function
- HST controller system
- Machine monitor system
- Rearview monitor system
- KOMTRAX system
- System component parts
- Sensor
- 20 Standard value tables
- Table of contents
- Standard service value table
- Standard value table for engine
- Standard value table for machine
- Standard value table for electrical system
- 30 Testing and adjusting
- Table of contents
- Related information on testing and adjusting
- Tools for testing and adjusting
- Sketch of tools for testing and adjusting
- Engine and cooling system
- Testing engine speed
- Testing boost pressure
- Testing exhaust gas temperature
- Testing exhaust gas color
- Test mass air flow and temperature sensor
- Testing and adjusting valve clearance
- Testing compression pressure
- Testing blowby pressure
- Testing engine oil pressure
- Testing EGR valve and KVGT oil pressures
- Testing fuel pressure
- Testing fuel discharge, return and leakage
- Bleeding air from fuel system
- Testing fuel circuit for leakage
- Handling cylinder cutout mode operation
- Handling no-injection cranking operation
- Testing of KDPF and muffler stack for looseness and damage
- Testing of installed condition of cylinder heads and manifolds
- Testing engine piping for damage and looseness
- Testing and adjusting air conditioner compressor belt tension
- Check alternator belt, replace
- Check auto-tensioner, replace
- Writing compensation amount for soot accumulation caused by ash on engine controller
- Power train
- Testing oil leakage from axle final drive
- Testing drive shaft for looseness, backlash, and damage
- Testing accelerator pedal
- Testing and adjusting HST oil pressure
- Testing transfer clutch control pressure
- Steering system
- Testing directional lever
- Testing steering wheel
- Testing work equipment control lever
- Testing and adjusting steering circuit oil pressure
- Bleeding air from steering cylinder circuit
- Brake system
- Testing brake pedal
- Testing braking performance
- Testing and adjusting of accumulator charge pressure
- Testing wheel brake oil pressure
- Testing lowering of wheel brake pressure
- Testing wear of wheel brake disc
- Bleeding air from wheel brake circuit
- Releasing remaining pressure in brake accumulator circuit
- Testing parking brake performance
- Testing wear of parking brake disc
- Testing parking brake release pressure
- Method of releasing parking brake manually
- Hydraulic system
- Testing cooling fan speed
- Testing cooling fan pump circuit oil pressure
- Bleeding air from hydraulic fan circuit
- Testing and adjusting work equipment PPC oil pressure
- Testing and adjusting work equipment oil pressure
- Bleeding air from work equipment circuit
- Releasing remaining pressure from work equipment circuit
- Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
- Work equipment
- Testing and adjusting bucket positioner and bucket proximity switch
- Testing and adjusting boom position detection lever
- Electrical system
- Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
- Special functions of machine monitor
- Adjusting rearview camera angle
- Handling voltage circuit of engine controller
- Handling battery disconnect switch
- Testing diodes
- Pm clinic
- Pm Clinic service
- Check sheet
- 40 Troubleshooting
- Table of contents
- Related information on troubleshooting
- Troubleshooting points
- Sequence of events in troubleshooting
- Checks before troubleshooting
- Inspection procedure before troubleshooting
- Preparation for troubleshooting of electrical system
- Classification and procedures for troubleshooting
- Symptom and troubleshooting numbers
- Information in troubleshooting table
- Procedure for troubleshooting wiring harness of pressure sensor system for open circuit
- Connector list and layout
- Connector contact identification
- T-branch box and T-branch adapter table
- Fuse location table
- Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
- Precautions when performing troubleshooting of machine monitor
- Processing procedure of harness checker for troubleshooting of machine monitor LCD unit
- Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors)
- Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135])
- Failure codes table
- Troubleshooting by failure code (Display of code)
- Failure code [2F00MA] Failure of Parking Brake Circuit
- Failure code [2F00MB] Malfunction of Parking Brake
- Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
- Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
- Failure code [6091NX] HST Oil Filter Clogging
- Failure code [7RHYKA] Disconnection of Fan Variable Control Sol.
- Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol.
- Failure code [7RHYKY] Hot Short of Fan Variable Control Sol.
- Failure code [879AKA] A/C Inner Sensor Open Circuit
- Failure code [879AKB] A/C Inner Sensor Short Circuit
- Failure code [879BKA] A/C Outer Sensor Open Circuit
- Failure code [879BKB] A/C Outer Sensor Short Circuit
- Failure code [879CKA] Ventilating Sensor Open Circuit
- Failure code [879CKB] Ventilating Sensor Short Circuit
- Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
- Failure code [879EMC] Ventilation Damper Abnormality
- Failure code [879FMC] Air Mix Damper Abnormality
- Failure code [989L00] Engine Controller Lock Caution 1
- Failure code [989M00] Engine Controller Lock Caution 2
- Failure code [989N00] Engine Controller Lock Caution 3
- Failure code [A1U0N3] HC Desorb Request 1
- Failure code [A1U0N4] HC Desorb Request 2
- Failure code [AA10NX] Air Cleaner Clogging
- Failure code [AB00KE] Charge Voltage Low
- Failure code [AB00KY] Hot Short of Alternator R Terminal
- Failure code [B@BAZG] Eng Oil Press Low
- Failure code [B@BAZK] Engine Oil Level Low
- Failure code [B@BCNS] Eng Water Overheat
- Failure code [B@BCZK] Eng Water Level Low
- Failure code [B@CRNS] HST Oil Temp. Overheat
- Failure code [CA115] Eng Ne and Bkup Speed Sens Error
- Failure code [CA122] Chg Air Press Sensor High Error
- Failure code [CA123] Chg Air Press Sensor Low Error
- Failure code [CA131] Throttle Sensor High Error
- Failure code [CA132] Throttle Sensor Low Error
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA187] Sensor 2 Supply Volt Low Error
- Failure code [CA221] Ambient Press Sensor High Error
- Failure code [CA222] Ambient Press Sensor Low Error
- Failure code [CA227] Sensor 2 Supply Volt High Error
- Failure code [CA234] Eng Overspeed
- Failure code [CA238] Ne Speed Sensor Supply Volt Error
- Failure code [CA239] Ne Speed Sens Supply Volt High Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA295] Ambient Press Sens In Range Error
- Failure code [CA322] Inj #1(L#1) Open/Short Error
- Failure code [CA323] Inj #5(L#5) Open/Short Error
- Failure code [CA324] Inj #3(L#3) Open/Short Error
- Failure code [CA325] Inj #6(L#6) Open/Short Error
- Failure code [CA331] Inj #2(L#2) Open/Short Error
- Failure code [CA332] Inj #4(L#4) Open/Short Error
- Failure code [CA343] ECM Critical Internal Failure
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sensor 1 Supply Volt Low Error
- Failure code [CA356] Mass Air Flow Sensor High Error
- Failure code [CA357] Mass Air Flow Sensor Low Error
- Failure code [CA386] Sensor 1 Supply Volt High Error
- Failure code [CA428] Water in Fuel Sensor High Error
- Failure code [CA429] Water in Fuel Sensor Low Error
- Failure code [CA431] Idle Validation Sw Error
- Failure code [CA432] Idle Validation Process Error
- Failure code [CA435] Eng Oil Press Sw Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA488] Chg Air Temp High Torque Derate
- Failure code [CA515] Rail Press Sens Sup Volt High Error
- Failure code [CA516] Rail Press Sens Sup Volt Low Error
- Failure code [CA553] Rail Press High Error
- Failure code [CA555] Crankcase Press High Error 1
- Failure code [CA556] Crankcase Press High Error 2
- Failure code [CA559] Rail Press Low Error
- Failure code [CA595] Turbo Speed High Error 2
- Failure code [CA687] Turbo Speed Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA691] Intake Air Temp Sens High Error
- Failure code [CA692] Intake Air Temp Sens Low Error
- Failure code [CA697] ECM Internal Temp Sensor High Error
- Failure code [CA698] ECM Int Temp Sensor Low Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA1117] Persistent Data Lost Error
- Failure code [CA1664] KDOC Malfunction
- Failure code [CA1691] Regeneration Ineffective
- Failure code [CA1695] Sensor 5 Supply Volt High Error
- Failure code [CA1696] Sensor 5 Supply Volt Low Error
- Failure code [CA1843] Crankcase Press Sens High Error
- Failure code [CA1844] Crankcase Press Sens Low Error
- Failure code [CA1879] KDPF Delta P Sensor High Error
- Failure code [CA1881] KDPF Delta P Sensor Low Error
- Failure code [CA1883] KDPF Delta P Sens In Range Error
- Failure code [CA1921] KDPF Soot Load High Error 1
- Failure code [CA1922] KDPF Soot Load High Error 2
- Failure code [CA1942] Crankcase Press Sens In Range Error
- Failure code [CA1993] KDPF Delta Pressure Low Error
- Failure code [CA2185] Throt Sensor Sup Volt High Error
- Failure code [CA2186] Throt Sensor Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [CA2271] EGR Valve Pos Sens High Error
- Failure code [CA2272] EGR Valve Pos Sens Low Error
- Failure code [CA2288] Turbo Speed High Error 1
- Failure code [CA2311] IMV Solenoid Error
- Failure code [CA2349] EGR Valve Solenoid Open Error
- Failure code [CA2353] EGR Valve Solenoid Short Error
- Failure code [CA2357] EGR Valve Servo Error
- Failure code [CA2373] Exhaust Manifold Press Sens High error
- Failure code [CA2374] Exhaust Manifold Press Sens Low error
- Failure code [CA2375] EGR Orifice Temp Sens High Error
- Failure code [CA2376] EGR Orifice Temp Sens Low Error
- Failure code [CA2381] KVGT Pos Sens High Error
- Failure code [CA2382] KVGT Pos Sens Low Error
- Failure code [CA2383] KVGT Solenoid Open Error
- Failure code [CA2386] KVGT Solenoid Short Error
- Failure code [CA2387] KVGT Servo Error
- Failure code [CA2554] Exh Manifold Press Sens In Range Error
- Failure code [CA2555] Grid Htr Relay Volt Low Error
- Failure code [CA2556] Grid Htr Relay Volt High Error
- Failure code [CA2637] KDOC Face Plugging
- Failure code [CA2639] Manual Stationary Regeneration Request
- Failure code [CA2961] EGR Orifice Temp High Error 1
- Failure code [CA2973] Chg Air Press Sensor In Range Error
- Failure code [CA3133] KDPF Outlet Press Sens High Error
- Failure code [CA3134] KDPF Outlet Press Sens Low Error
- Failure code [CA3135] KDPF Outlet Press Sens In Range Error
- Failure code [CA3251] KDOC Inlet Temp High Error
- Failure code [CA3253] KDOC Temp Error – Non Regeneration
- Failure code [CA3254] KDOC Outlet Temp High Error 1
- Failure code [CA3255] KDPF Temp Error – Non Regeneration
- Failure code [CA3256] KDPF Outlet Temp High Error 1
- Failure code [CA3311] KDOC Outlet Temp High Error 2
- Failure code [CA3312] KDPF Outlet Temp High Error 2
- Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
- Failure code [CA3314] KDOC Inlet Temp Sens High Error
- Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
- Failure code [CA3316] KDOC Outlet Temp Sens Low Error
- Failure code [CA3317] KDOC Outlet Temp Sens High Error
- Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
- Failure code [CA3319] KDPF Outlet Temp Sens High Error
- Failure code [CA3321] KDPF Outlet Temp Sens Low Error
- Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
- Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
- Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
- Failure code [CA3741] Rail Press Valve Trip Error
- Failure code [D110L4] Disconnection of Battery Relay Signal
- Failure code [D160KA] Disconnection of Backup Lamp Relay Output
- Failure code [D160KY] Hot Short of Backup Lamp Relay Output
- Failure code [D191KA] Disconnection of Neutral Output Relay
- Failure code [D191KB] Ground Fault of Neutral Output Relay
- Failure code [D191KY] Hot Short of Neutral Output Relay
- Failure code [D192KA] Disconnection of ECSS Solenoid
- Failure code [D192KB] Ground Fault of ECSS Solenoid
- Failure code [D192KY] Hot Short of ECSS Solenoid
- Failure code [D19JKZ] Personal Code Relay Abnormality
- Failure code [D1B0KA] Disconnection of HST Safety Relay
- Failure code [D1B0KB] Ground Fault of HST Safety Relay
- Failure code [D1B0KY] Hot Short of HST Safety Relay
- Failure code [D1B0MC] Malfunction of HST Safety Relay
- Failure code [D1E6KA] Disconnection of Parking Brake Relay
- Failure code [D1E6KB] Ground Fault of Parking Brake Relay
- Failure code [D1E6KY] Hot Short of Parking Brake Relay
- Failure code [D5ZHKA] Failure of Key SW C Signal
- Failure code [D5ZHKB] Key SW C Signal Short Circuit
- Failure code [D5ZHL6] Disconnection of Key SW C
- Failure code [D811MC] KOMTRAX Error
- Failure code [D862KA] GPS Antenna Open Circuit
- Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
- Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
- Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2
- Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
- Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)
- Failure code [DAF0MB] Monitor ROM Abnormality
- Failure code [DAF0MC] Monitor Error
- Failure code [DAF3KK] Controller Power Source Low (MON)
- Failure code [DAF8KB] Camera Power Supply Short Circuit
- Failure code [DAFDKB] Monitor 12V Power Output Short Circuit
- Failure code [DAFGMC] GPS Module Error
- Failure code [DAFLKA] Operating Lamp Open Circuit (MON)
- Failure code [DAFLKB] Operating Lamp Short Circuit (MON)
- Failure code [DAFQKR] CAN2 Discon (Monitor)
- Failure code [DAJ0KK] Controller Power Source Low (HST)
- Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST)
- Failure code [DAJ0MC] HST Con Error
- Failure code [DAJ1KA] Disconnection of Key SW ACC (HST)
- Failure code [DAJ2KK] Solenoid Power Source Low (HST)
- Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay
- Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay
- Failure code [DAJ5KX] Failure of 5V Power Source 0
- Failure code [DAJ6KX] Failure of 5V Power Source 1
- Failure code [DAJ9KQ] Inconsistency of Model Selection (HST)
- Failure code [DAJLKA] Operating Lamp Open Circuit (HST)
- Failure code [DAJLKB] Operating Lamp Short Circuit (HST)
- Failure code [DAJQKR] CAN2 Discon ( HST Con)
- Failure code [DAJRKR] CAN1 Discon ( HST Con)
- Failure code [DAJRMA] Inconsistency of Option Selection (HST)
- Failure code [DAZ9KQ] A/C Model Selection Abnormality
- Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
- Failure code [DB2QKR] CAN2 Discon (Engine Con)
- Failure code [DB2RKR] CAN1 Discon (Engine Con)
- Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW
- Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch
- Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction
- Failure code [DDB6L4] Parking Brake Signal Malfunction
- Failure code [DDD7KA] Failure of Variable Speed Control
- Failure code [DDD7KY] Hot Short of Variable Speed Control
- Failure code [DDK3KA] FNR SW Input Signal Disconnection
- Failure code [DDK3KB] FNR SW Input Signal Short Circuit
- Failure code [DDK6KA] FNR Lever Input Signal Disconnection
- Failure code [DDK6KB] FNR Lever Input Signal Short Circuit
- Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch
- Failure code [DF10KA] Disconnection of Speed Range Input
- Failure code [DF10KB] Ground Fault of Speed Range Input
- Failure code [DGH1KX] Out of Range of HST Oil Temp. Sensor
- Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor
- Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor
- Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit
- Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA)
- Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA)
- Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB)
- Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB)
- Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom)
- Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom)
- Failure code [DHPEKA] Failure of Steering & Loader Pump Press.
- Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press.
- Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit
- Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit
- Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit
- Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit
- Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit
- Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit
- Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit
- Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit
- Failure code [DHT8ZG] Steering Oil Pressure Low
- Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit
- Failure code [DJF1KA] Disconnection of Fuel Level Sensor
- Failure code [DK55KA] Failure of FNR Lever Potentio
- Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit
- Failure code [DK55L5] Failure of FNR Lever Potentio
- Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main)
- Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main)
- Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree
- Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub)
- Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub)
- Failure code [DK70KA] Failure of inching sensor Circuit
- Failure code [DK70KY] Hot Short of inching sensor Circuit
- Failure code [DKA0KA] Failure of Boom Angle Sensor
- Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit
- Failure code [DKA0L0] Boom Angle Sensor Dislocation
- Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor
- Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor
- Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B)
- Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A)
- Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B)
- Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B)
- Failure code [DPQ1KR] LIN Discon (Switch Panel)
- Failure code [DPQ2KR] LIN Discon (LED Unit)
- Failure code [DPQ3KR] LIN Discon (Rear View Monitor)
- Failure code [DSJ0KR] CAN2 Discon (Meter Unit)
- Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic.
- Failure code [DV00KB] Ground Fault of Buzzer Output
- Failure code [DW26KA] Disconnection of Motor 2 Solenoid
- Failure code [DW26KB] Ground Fault of Motor 2 Solenoid
- Failure code [DW26KY] Hot Short of Motor 2 Solenoid
- Failure code [DW4BKA] Disconnection of Parking Brake Valve
- Failure code [DW4BKB] Ground Fault of Parking Brake Valve
- Failure code [DW4BKY] Hot Short of Parking Brake Valve
- Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt)
- Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt)
- Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt)
- Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid
- Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid
- Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid
- Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom)
- Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom)
- Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom)
- Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket)
- Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)
- Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket)
- Failure code [DX19KA] Disconnection of Motor 1 Solenoid
- Failure code [DX19KB] Ground Fault of Motor 1 Solenoid
- Failure code [DX19KY] Hot Short of Motor 1 Solenoid
- Failure code [DX20KA] Disconnection of Clutch Control Solenoid
- Failure code [DX20KB] Ground Fault of Clutch Control Solenoid
- Failure code [DX20KY] Hot Short of Clutch Control Solenoid
- Failure code [DXAWKA] Disconnection of HST Pump EPC Sol.
- Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol.
- Failure code [DXAWKY] Hot Short of HST Pump EPC Sol.
- Failure code [DXH7KA] Disconnection of Reverse Solenoid
- Failure code [DXH7KB] Ground Fault of Reverse Solenoid
- Failure code [DXH7KY] Hot Short of Reverse Solenoid
- Failure code [DXH8KA] Disconnection of Forward Solenoid
- Failure code [DXH8KB] Ground Fault of Forward Solenoid
- Failure code [DXH8KY] Hot Short of Forward Solenoid
- Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)
- Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)
- Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)
- Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)
- Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)
- Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)
- Failure code [H2K0KA] Failure of Quick Coupler Lock Signal
- Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal
- Failure code [J141N1] Steering Pump Over Run
- Failure code [LA00L3] Failure of Fan Reverse
- Failure code [M100N1] HST Pump Over Run
- Failure code [M400N1] HST Motor 1 Over Run
- Troubleshooting of electrical system (E-mode)
- E-1 Engine does not start
- E-2 Manual preheating system does not work
- E-3 Automatic preheating system does not work
- E-4 While preheating is working, preheating monitor does not light up
- E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing
- E-6 LCD unit on machine monitor displays nothing
- E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers)
- E-8 LCD on machine monitor does not display properly
- E-9 Meter unit display on machine monitor is abnormal
- E-10 Night lighting lamp of meter unit on machine monitor is abnormal
- E-11 Caution LED on machine monitor is abnormal
- E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly
- E-13 Two switches operation of switch panel on machine monitor does not function
- E-14 Switch panel buzzer of machine monitor is abnormal
- E-15 Rearview monitor does not light up or backlight flickers
- E-16 Rearview monitor images are not displayed clearly
- E-17 Rearview monitor brightness cannot be adjusted
- E-18 Night lighting lamp of rearview monitor is abnormal
- E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly
- E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position
- E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light
- E-22 Air cleaner clogging indicator lamp does not light
- E-23 Radiator coolant level caution lamp does not light
- E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light
- E-25 When brake pedal (inching pedal) is depressed, inching function does not work (travel speed or traction force does not lower), or while not depressed, inching function operates
- E-26 Fuel level gauge does not indicate correct level
- E-27 Seat belt caution lamp indication is abnormal
- E-28 Horn does not sound
- E-29 Horn does not stop sounding
- E-30 Alarm buzzer does not sound
- E-31 When starting switch is in ON position, alarm buzzer does not stop sounding
- E-32 When emergency HST pump drive switch is operated, emergency HST pump does not work or when emergency HST pump drive switch is not operated, emergency HST pump works
- E-33 Setting does not change while operating traction control switch
- 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
- E-35 Remote positioner does not work or cannot be released
- E-36 Bucket positioner does not work or cannot be released
- E-37 Direction selector (FNR) switch mode is not selected or not released
- E-38 PZ auto tilt-in does not work
- E-39 Tracktion level does not display MAX when max traction switch is turned ON
- E-40 ECSS function cannot be selected or cannot be released
- E-41 None of headlamp, clearance lamp, and tail lamp lights
- E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out
- E-43 Both High and Low beams of headlamp do not light up or go out
- E-44 Low beam of headlamp does not light up or go out
- E-45 High beam of headlamp does not light up or go out
- E-46 Front working lamp does not light up or go out
- E-47 Rear working lamp does not light up or go out
- E-48 All of turn signal lamps and hazard lamps do not flash or go out
- E-49 Turn signal lamps do not flash or go out
- E-50 Hazard lamp does not flash or go out
- E-51 Brake lamp does not light or stays lighted
- E-52 Backup lamp does not light up or does not go out
- E-53 Backup buzzer does not sound or continues to sound
- E-54 Front wiper does not operate
- E-55 Rear wiper does not operate
- E-56 Window washer does not operate
- E-57 KOMTRAX system does not operate normally
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Information described in troubleshooting table (H-mode)
- System chart of hydraulic and mechanical systems
- Failure mode and cause table
- H-1 Machine does not travel forward or backward
- H-2 Machine does not travel forward (Machine travels backward normally)
- H-3 Machine does not travel backward (Machine travels forward normally)
- H-4 Machine does not travel forward or backward fast
- H-5 Machine does not travel forward fast (Machine travel backward fast)
- H-6 Machine does not travel backward fast (Machine travel forward fast)
- H-7 Machine lacks power neither when traveling forward nor backward
- H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward)
- H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward)
- H-10 Engine stalls during travel or engine speed drops significantly
- H-11 Steering wheel is too heavy to turn
- H-12 Steering wheel is heavy to turn
- H-13 Machine sways or large shocks are made while machine turns
- H-14 Machine unintentionally turns when machine travels
- H-15 Wheel brakes do not work or are weak
- H-16 Wheel brakes are not released or drag
- H-17 Parking brake does not work or it is weak
- H-18 Parking brake is not released or drags.
- H-19 Boom does not rise
- H-20 Boom moves slow or boom lacks lifting force
- H-21 Rising boom slows down at certain height
- H-22 Lift cylinders do not serve to hold bucket (bucket rises off ground)
- H-23 Hydraulic drift of boom is large
- H-24 Boom moves up and down during operation
- H-25 Bucket does not tilt back
- H-26 Bucket moves slow or lacks tilt force
- H-27 Bucket decelerates during tilt-back operation
- H-28 Bucket cylinder does not hold bucket on ground
- H-29 Hydraulic drift of bucket is large
- H-30 Bucket tilts back and forth during carrying load
- H-31 Boom and bucket control levers do not move smoothly and are heavy to move
- H-32 Operating work equipment causes engine speed to lower significantly or engine to stall
- H-33 Large shocks are made when work equipment starts to move and stops
- H-34 When certain work equipment is relieved hydraulically, other work equipment moves
- H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces
- H-36 Fan speed is abnormal (too high or low, or fan does not rotate)
- H-37 Unusual noise is heard from around fan
- Troubleshooting of engine (S-mode)
- Information described in troubleshooting table (S mode)
- S-1 Engine does not crank when starting switch is turned to START position
- S-2 Engine cranks but no exhaust smoke comes out
- S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)
- S-4 Engine startability is poor
- S-5 Engine does not pick up smoothly
- S-6 Engine stops during operation
- S-7 Engine runs rough or is unstable
- S-8 Engine lacks power
- S-9 KDPF gets clogged in a short time
- S-10 Engine oil consumption is excessive
- S-11 Engine oil becomes contaminated early
- S-12 Fuel consumption is excessive
- S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
- S-14 Oil pressure drops
- S-15 Fuel mixes into engine oil
- S-16 Water mixes into engine oil (milky)
- S-17 Coolant temperature rises too high (overheating)
- S-18 Unusual noise is heard
- S-19 Vibration is excessive
- S-20 Air cannot be bled from fuel circuit
- S-21 Active regeneration is executed frequently
- S-22 Active regeneration takes time
- S-23 White smoke is exhausted during active regeneration
- 50 Disassembly and assembly
- Table of contents
- Related information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Engine and cooling system
- Removal and installation of supply pump assembly
- Removal and installation of injector assembly
- Removal and installation of cylinder head assembly
- Removal and installation of engine hood assembly
- Removal and installation of radiator core assembly
- Removal and installation of aftercooler
- Removal and installation of hydraulic oil cooler
- Removal and installation of engine assembly
- Removal and installation of engine front oil seal
- Removal and installation of engine rear oil seal
- Removal and installation of cooling fan and fan motor assembly
- Removal and installation of KDPF assembly
- Disassembly and assembly of KDPF assembly
- Removal and installation of KCCV assembly
- Removal and installation of air cleaner assembly
- Removal and installation of KVGT assembly
- Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
- Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
- Removal and installation of alternator belt
- Removal and installation of fuel tank assembly
- Power train
- Removal and installation of transfer assembly
- Disassembly and assembly of transfer assembly
- Removal and installation of front axle assembly
- Removal and installation of rear axle assembly
- Disassembly and assembly of axle housing assembly
- Disassembly and assembly of differential assembly (Serial number: 80001 to 81412)
- Disassembly and assembly of differential assembly (Serial number: 81413 and up)
- Undercarriage and frame
- Removal and installation of center hinge pin
- Removal and installation of counterweight assembly
- Hydraulic system
- Removal and installation of hydraulic tank assembly
- Removal and installation of control valve assembly
- Disassembly and assembly of control valve assembly
- Removal and installation of hydraulic pump assembly
- Removal and installation of HST motor1 assembly
- Removal and installation of HST motor2 assembly
- Disassembly and assembly of hydraulic cylinder assembly
- Work equipment
- Removal and installation of work equipment assembly
- Cab and its attachments
- Removal and installation of operator's cab and floor frame assembly
- Removal and installation of operator's cab glass (adhered glass)
- Removal and installation of operator's seat assembly
- Removal and installation of seat belt
- Removal and installation of air conditioner unit assembly
- Removal and installation of air conditioner compressor
- Removal and installation of air conditioner condenser
- Electrical system
- Removal and installation of machine monitor assembly
- Removal and installation of engine controller assembly
- Removal and installation of HST controller assembly
- Removal and installation of air conditioner controller assembly
- Removal and installation of monitor controller assembly
- Removal and installation of mass air flow and temperature sensor
- Removal and installation of KOMTRAX terminal assembly
- 60 Maintenance standard
- Table of contents
- Engine and cooling system
- Engine related parts
- Cooling fan motor
- Power train
- Damper
- Transfer
- Drive shaft
- Axle
- Differential
- Limited slip differential
- Final drive
- Steering system
- Steering column
- Priority valve
- Emergency steering valve
- Steering cylinder
- Brake system
- Brake accumulator charge valve
- Slack adjuster
- Brake
- Parking brake
- Parking brake solenoid valve
- Undercarriage and frame
- Axle mount
- Center hinge pin
- Hydraulic system
- Hydraulic tank
- Double type gear pump
- Steering and work equipment pump
- Control valve
- Self-pressure reducing valve
- Work equipment PPC valve
- Work equipment lock solenoid valve
- Work equipment
- Work equipment linkage
- Bucket
- Work equipment cylinder
- Cab and its attachments
- Electrical system
- Bucket positioner
- Fork positioner
- Remote boom positioner
- 80 Appendix
- Table of contents
- Air conditioner components
- Precautions for refrigerant
- Air conditioner component
- Configuration and function of refrigeration cycle
- Outline of refrigeration cycle
- Air conditioner unit
- Dual pressure switch
- Air conditioner controller
- Compressor
- Condenser
- Receiver drier
- Sunlight sensor
- Outer temperature sensor (outside air temperature sensor)
- Procedure for testing and troubleshooting
- Circuit diagram and arrangement of connector pins
- System diagram
- Parts and connectors layout
- Testing with self-diagnosis function
- How to open the electrical system abnormality record screen in service mode of the machine monitor
- Testing temperature control system
- Testing vent (mode) changeover
- Testing FRESH/RECIRC air changeover
- Testing evaporator temperature sensor
- Testing relays
- Troubleshooting chart 1
- Troubleshooting chart 2
- Information in troubleshooting table
- Failure code list related to air conditioner
- Failure code [879AKA] A/C Inner Sensor Open Circuit
- Failure code [879AKB] A/C Inner Sensor Short Circuit
- Failure code [879BKA] A/C Outer Sensor Open Circuit
- Failure code [879BKB] A/C Outer Sensor Short Circuit
- Failure code [879CKA] Ventilating Sensor Open Circuit
- Failure code [879CKB] Ventilating Sensor Short Circuit
- Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
- Failure code [879EMC] Ventilation Damper Abnormality
- Failure code [879FMC] Air Mix Damper Abnormality
- A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
- A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
- A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
- A-4 Troubleshooting for FRESH/RECIRC air changeover
- Troubleshooting with gauge pressure
- Connection of service tool
- Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
- Handling of compressor oil
- 90 Diagrams and drawings
- Table of contents
- Hydraulic circuit diagram
- Symbols in hydraulic circuit diagram
- Hydraulic circuit diagram
- Electric circuit diagram
- Symbols in electric circuit diagram
- Electrical circuit diagram of machine body
- Electrical circuit diagram of floor
- INDEX
Komatsu
