Komatsu WA200-8 Wheel Loader Shop Manual VENBM32500 PDF

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Komatsu WA200-8 Wheel Loader Shop Manual VENBM32500 – PDF DOWNLOAD

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Komatsu WA200-8 Wheel Loader Shop Manual VENBM32500 – PDF DOWNLOAD 

Language : English
Pages : 2988
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA200-8 Wheel Loader Shop Manual VENBM32500 – PDF DOWNLOAD 

SERIAL NUMBERS

H80051 and up
85001 and up

VENAM32500_WA200-8_CSSNET_2018-03-08 pdf 1
Cover_WA200-8-SM-A4 1
VENAM32500_WA200-8_A2 3
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 21
FOREWORD, SAFETY, BASIC INFORMATION 27
HOW TO READ THE SHOP MANUAL 27
SAFETY NOTICE FOR OPERATION 29
PRECAUTIONS TO PREVENT FIRE 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 41
PRECAUTIONS FOR DEF 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 42
THE OTHER PRECAUTIONS 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS 93
CONTENTS 94
ABBREVIATION LIST 95
SPECIFICATIONS 101
SPECIFICATION DRAWING 101
SPECIFICATION DRAWING: WA200-8 101
SPECIFICATIONS 103
SPECIFICATIONS: WA200-8 103
WEIGHT TABLE 109
WEIGHT TABLE: WA200-8 109
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 111
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 111
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 113
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 113
10 STRUCTURE AND FUNCTION 115
CONTENTS 116
ABBREVIATION LIST 120
UREA SCR SYSTEM 126
LAYOUT DRAWING OF UREA SCR SYSTEM 126
UREA SCR SYSTEM DIAGRAM 128
FUNCTION OF UREA SCR SYSTEM 129
FUNCTION OF AdBlue/DEF SYSTEM 129
INDUCEMENT STRATEGY 132
COMPONENT PARTS OF UREA SCR SYSTEM 146
AdBlue/DEF MIXING TUBE 146
SCR ASSEMBLY 147
AdBlue/DEF TANK 149
AdBlue/DEF PUMP 151
AdBlue/DEF INJECTOR 152
AdBlue/DEF HOSE 153
AdBlue/DEF TANK HEATING VALVE 154
BOOT-UP SYSTEM 155
LAYOUT DRAWING OF BOOT-UP SYSTEM 155
SYSTEM OPERATING LAMP SYSTEM 157
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 157
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 157
BATTERY DISCONNECT SWITCH 158
FUNCTION OF BATTERY DISCONNECT SWITCH 158
PREHEATING SYSTEM 159
PREHEATING SYSTEM DIAGRAM 159
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 159
OPERATION OF AUTOMATIC PREHEATING SYSTEM 159
FUNCTION OF MANUAL PREHEATING SYSTEM 160
OPERATION OF MANUAL PREHEATING SYSTEM 160
ENGINE SYSTEM 161
LAYOUT DRAWING OF ENGINE SYSTEM 161
FUNCTION OF ENGINE SYSTEM 162
ENGINE CONTROL SYSTEM 163
ENGINE CONTROL SYSTEM DIAGRAM 163
FUNCTION OF ENGINE CONTROL SYSTEM 165
OPERATION OF ENGINE CONTROL SYSTEM 168
AUTOMATIC IDLE STOP SYSTEM 170
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 170
COMPONENT PARTS OF ENGINE SYSTEM 171
DAMPER 171
VGT 172
EGR SYSTEM 175
EGR VALVE 177
EGR COOLER 179
KCCV SYSTEM 181
KCCV VENTILATOR 183
KDOC 185
COOLING SYSTEM 188
LAYOUT DRAWING OF COOLING SYSTEM 188
SPECIFICATIONS OF COOLING SYSTEM 189
COOLING FAN CONTROL SYSTEM 190
COOLING FAN CONTROL SYSTEM DIAGRAM 190
FUNCTION OF COOLING FAN CONTROL SYSTEM 190
COMPONENT PARTS OF COOLING SYSTEM 195
COOLING FAN MOTOR 195
HYDRAULIC OIL COOLER BYPASS VALVE 205
CONTROL SYSTEM 206
LAYOUT DRAWING OF CONTROL SYSTEM 206
MACHINE MONITOR SYSTEM 208
MACHINE MONITOR SYSTEM DIAGRAM 208
FUNCTION OF MACHINE MONITOR SYSTEM 208
REARVIEW MONITOR SYSTEM 210
REARVIEW MONITOR SYSTEM DIAGRAM 210
FUNCTION OF REARVIEW MONITOR SYSTEM 210
KOMTRAX SYSTEM 211
KOMTRAX SYSTEM DIAGRAM 211
FUNCTION OF KOMTRAX SYSTEM 211
COMPONENT PARTS OF CONTROL SYSTEM 212
MACHINE MONITOR 212
SWITCH PANEL 229
REARVIEW MONITOR 230
REARVIEW CAMERA 232
KOMTRAX TERMINAL 233
MONITOR CONTROLLER 235
HST CONTROLLER 240
CAN TERMINATING RESISTOR 244
ENGINE CONTROLLER 245
ACCELERATOR PEDAL 252
HYDRAULIC SYSTEM 254
LAYOUT DRAWING OF HYDRAULIC SYSTEM 254
COMPONENT PARTS OF HYDRAULIC SYSTEM 255
HYDRAULIC TANK 255
HYDRAULIC OIL FILTER 257
STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP 258
CONTROL VALVE 260
POWER TRAIN SYSTEM 281
LAYOUT DRAWING OF POWER TRAIN SYSTEM 281
OPERATION OF POWER TRAIN SYSTEM 283
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 284
HST CONTROL SYSTEM 286
HST CONTROL SYSTEM DIAGRAM 286
ENGINE OVERRUN PREVENTION FUNCTION 287
NEUTRALIZER FUNCTION 287
SECONDARY HST TRAVEL FUNCTION 287
HST CHARGE SYSTEM 288
SYSTEM DIAGRAM OF HST CHARGE SYSTEM 288
FUNCTION OF HST CHARGE SYSTEM 288
HST PUMP CONTROL SYSTEM 289
SYSTEM DIAGRAM OF HST PUMP CONTROL SYSTEM 289
DIRECTIONAL SELECTION FUNCTION 289
INCHING CONTROL FUNCTION 289
TRAVEL SPEED ADJUSTMENT FUNCTION (AT LOW SPEED) 290
HST CONTROLLER GEAR SHIFT CONTROL FUNCTION 291
GEAR SHIFT FUNCTION 291
GEAR SHIFT DISPLAY FUNCTION 293
TRAVEL SPEED ADJUSTMENT FUNCTION 293
TRANSFER CLUTCH CONTROL FUNCTION 294
HST SYSTEM PROTECTION FUNCTION 295
DIRECTION PROTECTION FUNCTION 295
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 1 295
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 2 296
TRAVEL SPEED LIMITATION FUNCTION 296
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 297
KOMATSU TRACTION CONTROL SYSTEM (KTCS) DIAGRAM 297
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 297
COMPONENT PARTS OF POWER TRAIN SYSTEM 301
DRIVE SHAFT 301
HST PUMP 303
HST CHARGE PUMP 311
HST MOTOR 313
TRANSFER 322
AXLE 330
TORQUE PROPORTIONING DIFFERENTIAL 332
LIMITED SLIP DIFFERENTIAL 336
FINAL DRIVE 340
COMBINATION SWITCH 342
WORK EQUIPMENT SYSTEM 346
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 346
WORK EQUIPMENT CONTROL SYSTEM 348
WORK EQUIPMENT LEVER OPERATION FUNCTION 348
WORK EQUIPMENT LOCK SYSTEM 349
WORK EQUIPMENT LOCK SYSTEM DIAGRAM 349
FUNCTION OF WORK EQUIPMENT LOCK SYSTEM 349
BUCKET POSITIONER SYSTEM 351
BUCKET POSITIONER SYSTEM DIAGRAM 351
FUNCTION OF BUCKET POSITIONER SYSTEM 351
OPERATION OF BUCKET POSITIONER SYSTEM 352
BOOM KICK-OUT SYSTEM 354
SYSTEM DRAWING OF BOOM KICK-OUT SYSTEM 354
FUNCTION OF BOOM KICK-OUT SYSTEM 354
OPERATION OF BOOM KICK-OUT SYSTEM 355
ECSS 357
ECSS DIAGRAM 357
FUNCTION OF ECSS 357
OPERATION OF ECSS 357
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 359
WORK EQUIPMENT LOCK SOLENOID VALVE 359
ATTACHMENT EPC SOLENOID VALVE 360
PILOT CIRCUIT ACCUMULATOR 361
ECSS CIRCUIT ACCUMULATOR 362
MULTIFUNCTION MONO-LEVER 363
MULTIFUNCTION MONO-LEVER PPC VALVE 365
QUICK COUPLER SOLENOID VALVE 370
STEERING SYSTEM 371
LAYOUT DRAWING OF STEERING SYSTEM 371
STEERING COLUMN 372
STRUCTURE OF STEERING COLUMN 372
COMPONENT PARTS OF STEERING SYSTEM 373
PRIORITY VALVE 373
ORBITROL VALVE 376
CUSHION VALVE 383
2-WAY RESTRICTOR VALVE 385
SECONDARY STEERING VALVE 386
BRAKE SYSTEM 389
LAYOUT DRAWING OF BRAKE SYSTEM 389
PARKING BRAKE CONTROL SYSTEM 391
PARKING BRAKE CONTROL SYSTEM DIAGRAM 391
OPERATION OF PARKING BRAKE CONTROL SYSTEM 391
COMPONENT PARTS OF BRAKE SYSTEM 394
BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE 394
PARKING BRAKE SOLENOID VALVE 398
BRAKE CIRCUIT ACCUMULATOR 400
BRAKE VALVE 402
SLACK ADJUSTER 406
BRAKE 408
PARKING BRAKE 411
PARKING BRAKE CYLINDER 412
UNDERCARRIAGE AND FRAME 413
FRAME, AXLE MOUNT AND CENTER HINGE PIN 413
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 413
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 414
TIRE 416
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 416
STRUCTURE OF RADIAL TIRE 416
FUNCTION OF RADIAL TIRE 416
STRUCTURE OF BIAS TIRE 417
FUNCTION OF BIAS TIRE 417
WORK EQUIPMENT 418
STRUCTURE OF WORK EQUIPMENT 418
STRUCTURE OF BUCKET 419
CAB AND ITS ATTACHMENTS 420
ROPS CAB 420
STRUCTURE OF ROPS CAB 420
FUNCTION OF ROPS CAB 420
CAB MOUNT 421
STRUCTURE OF CAB MOUNT 421
FUNCTION OF CAB MOUNT 421
20 STANDARD VALUE TABLE 423
CONTENTS 424
ABBREVIATION LIST 425
STANDARD VALUE TABLE FOR ENGINE 431
STANDARD VALUE TABLE FOR ENGINE: WA200-8 431
STANDARD VALUE TABLE FOR MACHINE 436
STANDARD VALUE TABLE FOR MACHINE: WA200-8 436
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 448
30 TESTING AND ADJUSTING 451
CONTENTS 452
ABBREVIATION LIST 455
RELATED INFORMATION ON TESTING AND ADJUSTING 461
TOOLS FOR TESTING AND ADJUSTING 461
ENGINE AND COOLING SYSTEM 469
TEST ENGINE SPEED 469
METHOD FOR TESTING ENGINE SPEED 469
TEST BOOST PRESSURE 472
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 472
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 473
TEST EXHAUST GAS COLOR 475
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 475
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 476
TEST AND ADJUST VALVE CLEARANCE 478
METHOD FOR TESTING VALVE CLEARANCE 478
METHOD FOR ADJUSTING VALVE CLEARANCE 479
TEST COMPRESSION PRESSURE 481
METHOD FOR TESTING COMPRESSION PRESSURE 481
TEST BLOWBY PRESSURE 486
METHOD FOR TESTING BLOWBY PRESSURE 486
TEST ENGINE OIL PRESSURE 489
METHOD FOR TESTING ENGINE OIL PRESSURE 489
TEST FUEL PRESSURE 491
METHOD FOR TESTING FUEL PRESSURE 492
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 496
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 497
BLEED AIR FROM FUEL SYSTEM 502
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 502
TEST FUEL CIRCUIT FOR LEAKAGE 504
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 504
HANDLE CYLINDER CUT-OUT MODE OPERATION 506
HANDLE NO-INJECTION CRANKING OPERATION 507
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 508
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 508
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 509
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 509
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 510
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 510
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 511
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 511
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 511
TEST ALTERNATOR BELT 513
METHOD FOR TESTING ALTERNATOR BELT 513
TEST AUTOMATIC TENSIONER 515
METHOD FOR TESTING AUTOMATIC TENSIONER 515
TEST SCR RELATED FUNCTIONS 518
TEST AdBlue/DEF PUMP RAISED PRESSURE 522
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 525
TEST AdBlue/DEF LINE HEATER RELAY 1 531
TEST AdBlue/DEF LINE HEATER RELAY 2 535
TEST AdBlue/DEF PUMP HEATER RELAY 539
TEST AdBlue/DEF TANK HEATER VALVE 543
TEST SCR NOx REMOVAL EFFICIENCY 547
CLEAN AdBlue/DEF TANK 550
METHOD FOR CLEANING AdBlue/DEF TANK 550
POWER TRAIN 555
TEST AND ADJUST HST OIL PRESSURE 555
METHOD FOR TESTING HST OIL PRESSURE 555
METHOD FOR ADJUSTING HST OIL PRESSURE 558
TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH 560
METHOD FOR TESTING THE CONTROL PRESSURE OF TRANSFER CLUTCH 560
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 562
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 562
STEERING SYSTEM 563
TEST STEERING WHEEL 563
METHOD FOR TESTING STEERING WHEEL 563
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 565
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 565
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 566
BLEED AIR FROM STEERING CYLINDER CIRCUIT 568
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 568
BRAKE SYSTEM 569
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 569
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 569
TEST WHEEL BRAKE OIL PRESSURE 570
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 570
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 572
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE 572
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE 573
BLEED AIR FROM BRAKE CIRCUIT 574
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 574
TEST BRAKING PERFORMANCE 575
METHOD FOR TESTING BRAKING PERFORMANCE 575
TEST BRAKE PEDAL 576
METHOD FOR TESTING BRAKE PEDAL 576
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 577
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE 577
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE 577
TEST LOWERING OF WHEEL BRAKE PRESSURE 578
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 579
TEST WEAR OF WHEEL BRAKE DISC 581
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 581
TEST PARKING BRAKE OIL PRESSURE 583
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 583
TEST PARKING BRAKE PERFORMANCE 585
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 585
RELEASE PARKING BRAKE MANUALLY 586
METHOD FOR RELEASING PARKING BRAKE MANUALLY 586
HYDRAULIC SYSTEM 587
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 587
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 587
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 589
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 589
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 590
TEST WORK EQUIPMENT PPC OIL PRESSURE 592
METHOD FOR TESTING WORK EQUIPMENT PPC OIL PRESSURE 592
BLEED AIR FROM WORK EQUIPMENT PPC CIRCUIT 594
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT PPC CIRCUIT 594
TEST COOLING FAN SPEED 595
METHOD FOR TESTING COOLING FAN SPEED 595
TEST COOLING FAN CIRCUIT OIL PRESSURE 596
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 596
BLEED AIR FROM COOLING FAN CIRCUIT 598
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 598
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 600
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 600
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS 602
WORK EQUIPMENT 605
TEST AND ADJUST BUCKET POSITIONER 605
METHOD FOR TESTING BUCKET POSITIONER 605
METHOD FOR ADJUSTING BUCKET POSITIONER 605
CAB AND ITS ATTACHMENTS 607
TEST DIRECTIONAL LEVER 607
METHOD FOR TESTING DIRECTIONAL LEVER 607
TEST MULTIFUNCTION MONO-LEVER 608
METHOD FOR TESTING MULTIFUNCTION MONO-LEVER 608
TEST ACCELERATOR PEDAL 610
METHOD FOR TESTING ACCELERATOR PEDAL 610
ELECTRICAL SYSTEM 612
SET AND ADJUST EACH EQUIPMENT 612
SET AND OPERATE MACHINE MONITOR 614
OPERATOR MODE 618
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 618
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 618
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 619
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 620
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 620
SERVICE MODE 624
METHOD FOR OPERATING SERVICE MODE 624
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 626
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 632
ABNORMALITY RECORD MENU 644
METHOD FOR CONFIRMING MAINTENANCE RECORD 649
METHOD FOR OPERATING MAINTENANCE MODE SETTING 651
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 656
DEFAULT MENU 658
DIAGNOSTIC TESTS MENU 672
ADJUSTMENT MENU 680
METHOD FOR PERFORMING NO-INJECTION CRANKING 700
KOMTRAX SETTINGS MENU 702
METHOD FOR DISPLAYING SERVICE MESSAGE 704
METHOD FOR STARTING UP KOMTRAX TERMINAL 706
ADJUST REARVIEW CAMERA ANGLE 711
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 711
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 713
HANDLE BATTERY DISCONNECT SWITCH 714
TEST DIODES 715
METHOD FOR TESTING DIODE USING DIGITAL TESTER 715
METHOD FOR TESTING DIODE USING ANALOG TESTER 715
Pm CLINIC 716
Pm CLINIC SERVICE 716
Pm CLINIC CHECK SHEET: WA200-8 718
40 TROUBLESHOOTING 727
CONTENTS 728
ABBREVIATION LIST 738
RELATED INFORMATION ON TROUBLESHOOTING 744
GENERAL TROUBLESHOOTING POINTS 744
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 745
SEQUENCE OF EVENTS IN TROUBLESHOOTING 757
CHECKS BEFORE TROUBLESHOOTING 759
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 761
WALK-AROUND CHECK 761
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 763
CHECK FUEL LEVEL AND TYPE 763
FUEL – CHECK FOR FOREIGN MATERIAL 763
CHECK AdBule/DEF LEVEL AND TYPE 764
CHECK FUEL PREFILTER 764
CHECK MAIN FILTER 766
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 768
CHECK COOLANT LEVEL (RESERVOIR TANK) 769
CHECK CLOGGING OF AIR CLEANER 770
OUTER ELEMENT – CLEAN 771
REPLACE ELEMENT 773
CHECK HYDRAULIC OIL LEVEL 775
CHECK HYDRAULIC FILTER 777
CHECK THE OIL LEVEL IN THE TRANSFER CASE 778
CHECK OIL LEVEL IN FRONT AXLE CASE 779
CHECK OIL LEVEL IN REAR AXLE CASE 780
BLEED AIR FROM FUEL SYSTEM 781
BLEED AIR FROM HYDRAULIC SYSTEM 781
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 781
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 788
PROCEDURE FOR TESTING AND TROUBLESHOOTING 796
SYMPTOM AND TROUBLESHOOTING NUMBERS 798
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 802
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 804
CONNECTORS LIST AND LAYOUT 807
CONNECTOR CONTACT IDENTIFICATION 824
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 863
FUSE LOCATION TABLE 869
PRECAUTIONS FOR REPLACING KDOC 873
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 874
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 876
FAILURE CODES TABLE 882
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 900
FAILURE CODE [2F00MA] 900
FAILURE CODE [2F00MB] 903
FAILURE CODE [2G42ZG] 905
FAILURE CODE [2G43ZG] 907
FAILURE CODE [6091NX] 909
FAILURE CODE [7RHYKA] 911
FAILURE CODE [7RHYKB] 913
FAILURE CODE [7RHYKY] 915
FAILURE CODE [879AKA] 917
FAILURE CODE [879AKB] 919
FAILURE CODE [879BKA] 921
FAILURE CODE [879BKB] 923
FAILURE CODE [879CKA] 925
FAILURE CODE [879CKB] 927
FAILURE CODE [879DKZ] 929
FAILURE CODE [879EMC] 931
FAILURE CODE [879FMC] 932
FAILURE CODE [989FN1] 933
FAILURE CODE [989L00] 934
FAILURE CODE [989M00] 935
FAILURE CODE [989N00] 936
FAILURE CODE [A1U0N3] 937
FAILURE CODE [A1U0N4] 939
FAILURE CODE [AB00KE] 941
FAILURE CODE [AB00KY] 943
FAILURE CODE [AQ10MB] 945
FAILURE CODE [AQ10N3] 947
FAILURE CODE [AS00R2] 949
FAILURE CODE [AS00R3] 950
FAILURE CODE [AS00R4] 951
FAILURE CODE [AS00R5] 952
FAILURE CODE [AS00R6] 953
FAILURE CODE [AS00ZK] 954
FAILURE CODE [AS10KM] 955
FAILURE CODE [AS10NR] 956
FAILURE CODE [AS10NT] 957
FAILURE CODE [B@BAZG] 958
FAILURE CODE [B@BCNS] 959
FAILURE CODE [B@BCZK] 960
FAILURE CODE [B@C6NS] 962
FAILURE CODE [B@CRNS] 964
FAILURE CODE [CA115] 965
FAILURE CODE [CA122] 966
FAILURE CODE [CA123] 968
FAILURE CODE [CA131] 970
FAILURE CODE [CA132] 972
FAILURE CODE [CA144] 975
FAILURE CODE [CA145] 977
FAILURE CODE [CA153] 979
FAILURE CODE [CA154] 981
FAILURE CODE [CA187] 983
FAILURE CODE [CA221] 985
FAILURE CODE [CA222] 987
FAILURE CODE [CA227] 989
FAILURE CODE [CA234] 991
FAILURE CODE [CA238] 992
FAILURE CODE [CA239] 993
FAILURE CODE [CA249] 994
FAILURE CODE [CA256] 996
FAILURE CODE [CA271] 998
FAILURE CODE [CA272] 1000
FAILURE CODE [CA295] 1002
FAILURE CODE [CA322] 1003
FAILURE CODE [CA324] 1005
FAILURE CODE [CA331] 1007
FAILURE CODE [CA332] 1009
FAILURE CODE [CA343] 1011
FAILURE CODE [CA351] 1012
FAILURE CODE [CA352] 1013
FAILURE CODE [CA356] 1015
FAILURE CODE [CA357] 1017
FAILURE CODE [CA386] 1019
FAILURE CODE [CA428] 1020
FAILURE CODE [CA429] 1022
FAILURE CODE [CA431] 1024
FAILURE CODE [CA432] 1027
FAILURE CODE [CA435] 1031
FAILURE CODE [CA441] 1033
FAILURE CODE [CA442] 1035
FAILURE CODE [CA451] 1036
FAILURE CODE [CA452] 1038
FAILURE CODE [CA488] 1040
FAILURE CODE [CA515] 1041
FAILURE CODE [CA516] 1043
FAILURE CODE [CA553] 1045
FAILURE CODE [CA555] 1046
FAILURE CODE [CA556] 1047
FAILURE CODE [CA559] 1048
FAILURE CODE [CA595] 1051
FAILURE CODE [CA687] 1053
FAILURE CODE [CA689] 1055
FAILURE CODE [CA691] 1058
FAILURE CODE [CA692] 1060
FAILURE CODE [CA697] 1062
FAILURE CODE [CA698] 1063
FAILURE CODE [CA731] 1064
FAILURE CODE [CA778] 1066
FAILURE CODE [CA1117] 1070
FAILURE CODE [CA1664] 1072
FAILURE CODE [CA1669] 1074
FAILURE CODE [CA1673] 1075
FAILURE CODE [CA1677] 1076
FAILURE CODE [CA1678] 1077
FAILURE CODE [CA1682] 1078
FAILURE CODE [CA1683] 1082
FAILURE CODE [CA1684] 1084
FAILURE CODE [CA1686] 1086
FAILURE CODE [CA1691] 1087
FAILURE CODE [CA1694] 1089
FAILURE CODE [CA1695] 1091
FAILURE CODE [CA1696] 1092
FAILURE CODE [CA1712] 1095
FAILURE CODE [CA1713] 1098
FAILURE CODE [CA1714] 1100
FAILURE CODE [CA1715] 1101
FAILURE CODE [CA1776] 1102
FAILURE CODE [CA1777] 1105
FAILURE CODE [CA1843] 1108
FAILURE CODE [CA1844] 1110
FAILURE CODE [CA1885] 1113
FAILURE CODE [CA1887] 1115
FAILURE CODE [CA1896] 1117
FAILURE CODE [CA1898] 1118
FAILURE CODE [CA1938] 1120
FAILURE CODE [CA1942] 1122
FAILURE CODE [CA1961] 1123
FAILURE CODE [CA1962] 1124
FAILURE CODE [CA2185] 1125
FAILURE CODE [CA2186] 1127
FAILURE CODE [CA2198] 1129
FAILURE CODE [CA2272] 1130
FAILURE CODE [CA2288] 1132
FAILURE CODE [CA2311] 1133
FAILURE CODE [CA2349] 1134
FAILURE CODE [CA2353] 1136
FAILURE CODE [CA2357] 1138
FAILURE CODE [CA2373] 1139
FAILURE CODE [CA2374] 1141
FAILURE CODE [CA2375] 1143
FAILURE CODE [CA2376] 1145
FAILURE CODE [CA2387] 1148
FAILURE CODE [CA2554] 1149
FAILURE CODE [CA2555] 1150
FAILURE CODE [CA2556] 1152
FAILURE CODE [CA2634] 1154
FAILURE CODE [CA2635] 1156
FAILURE CODE [CA2636] 1157
FAILURE CODE [CA2637] 1159
FAILURE CODE [CA2771] 1161
FAILURE CODE [CA2961] 1165
FAILURE CODE [CA2973] 1166
FAILURE CODE [CA2976] 1167
FAILURE CODE [CA3142] 1169
FAILURE CODE [CA3143] 1170
FAILURE CODE [CA3144] 1171
FAILURE CODE [CA3146] 1174
FAILURE CODE [CA3147] 1175
FAILURE CODE [CA3148] 1176
FAILURE CODE [CA3151] 1179
FAILURE CODE [CA3165] 1187
FAILURE CODE [CA3228] 1189
FAILURE CODE [CA3229] 1191
FAILURE CODE [CA3231] 1193
FAILURE CODE [CA3232] 1195
FAILURE CODE [CA3235] 1199
FAILURE CODE [CA3239] 1201
FAILURE CODE [CA3241] 1204
FAILURE CODE [CA3242] 1207
FAILURE CODE [CA3251] 1210
FAILURE CODE [CA3313] 1212
FAILURE CODE [CA3314] 1213
FAILURE CODE [CA3315] 1214
FAILURE CODE [CA3419] 1216
FAILURE CODE [CA3421] 1218
FAILURE CODE [CA3497] 1220
FAILURE CODE [CA3498] 1221
FAILURE CODE [CA3545] 1222
FAILURE CODE [CA3547] 1224
FAILURE CODE [CA3558] 1225
FAILURE CODE [CA3559] 1227
FAILURE CODE [CA3562] 1229
FAILURE CODE [CA3563] 1231
FAILURE CODE [CA3567] 1234
FAILURE CODE [CA3568] 1238
FAILURE CODE [CA3571] 1244
FAILURE CODE [CA3572] 1246
FAILURE CODE [CA3574] 1248
FAILURE CODE [CA3575] 1251
FAILURE CODE [CA3577] 1253
FAILURE CODE [CA3578] 1255
FAILURE CODE [CA3582] 1257
FAILURE CODE [CA3583] 1264
FAILURE CODE [CA3596] 1266
FAILURE CODE [CA3649] 1269
FAILURE CODE [CA3681] 1271
FAILURE CODE [CA3682] 1276
FAILURE CODE [CA3713] 1281
FAILURE CODE [CA3717] 1284
FAILURE CODE [CA3718] 1285
FAILURE CODE [CA3724] 1286
FAILURE CODE [CA3725] 1287
FAILURE CODE [CA3741] 1290
FAILURE CODE [CA3748] 1291
FAILURE CODE [CA3755] 1293
FAILURE CODE [CA3866] 1295
FAILURE CODE [CA3868] 1298
FAILURE CODE [CA4152] 1302
FAILURE CODE [CA4155] 1306
FAILURE CODE [CA4156] 1309
FAILURE CODE [CA4157] 1312
FAILURE CODE [CA4159] 1314
FAILURE CODE [CA4164] 1315
FAILURE CODE [CA4165] 1317
FAILURE CODE [CA4166] 1319
FAILURE CODE [CA4168] 1320
FAILURE CODE [CA4169] 1323
FAILURE CODE [CA4171] 1325
FAILURE CODE [CA4249] 1327
FAILURE CODE [CA4251] 1329
FAILURE CODE [CA4261] 1331
FAILURE CODE [CA4277] 1334
FAILURE CODE [CA4459] 1337
FAILURE CODE [CA4461] 1339
FAILURE CODE [CA4533] 1342
FAILURE CODE [CA4534] 1343
FAILURE CODE [CA4731] 1344
FAILURE CODE [CA4732] 1345
FAILURE CODE [CA4739] 1346
FAILURE CODE [CA4768] 1347
FAILURE CODE [CA4769] 1349
FAILURE CODE [CA4842] 1352
FAILURE CODE [CA4952] 1355
FAILURE CODE [CA5115] 1357
FAILURE CODE [CA5179] 1360
FAILURE CODE [CA5181] 1362
FAILURE CODE [CA5387] 1364
FAILURE CODE [CA5388] 1366
FAILURE CODE [CA5389] 1369
FAILURE CODE [CA5391] 1371
FAILURE CODE [CA5392] 1375
FAILURE CODE [CA5393] 1377
FAILURE CODE [CA5394] 1380
FAILURE CODE [CA5395] 1383
FAILURE CODE [CA5396] 1386
FAILURE CODE [CA5631] 1387
FAILURE CODE [CA5632] 1389
FAILURE CODE [CA5938] 1390
FAILURE CODE [D110L4] 1392
FAILURE CODE [D160KA] 1394
FAILURE CODE [D160KY] 1396
FAILURE CODE [D191KA] 1397
FAILURE CODE [D191KB] 1399
FAILURE CODE [D191KY] 1401
FAILURE CODE [D192KA] 1402
FAILURE CODE [D192KB] 1403
FAILURE CODE [D192KY] 1404
FAILURE CODE [D19JKZ] 1405
FAILURE CODE [D1B0KA] 1407
FAILURE CODE [D1B0KB] 1409
FAILURE CODE [D1B0KY] 1411
FAILURE CODE [D1B0MC] 1413
FAILURE CODE [D1E6KA] 1415
FAILURE CODE [D1E6KB] 1417
FAILURE CODE [D1E6KY] 1419
FAILURE CODE [D5ZHKA] 1421
FAILURE CODE [D5ZHKB] 1423
FAILURE CODE [D5ZHL6] 1425
FAILURE CODE [D811MC] 1427
FAILURE CODE [D862KA] 1428
FAILURE CODE [D8ALKA] 1429
FAILURE CODE [D8ALKB] 1431
FAILURE CODE [D8AQK4] 1433
FAILURE CODE [D8AQKR] 1437
FAILURE CODE [DAF0KT] 1441
FAILURE CODE [DAF0MB] 1442
FAILURE CODE [DAF0MC] 1443
FAILURE CODE [DAF3KK] 1444
FAILURE CODE [DAF8KB] 1446
FAILURE CODE [DAFDKB] 1448
FAILURE CODE [DAFGMC] 1450
FAILURE CODE [DAFLKA] 1451
FAILURE CODE [DAFLKB] 1453
FAILURE CODE [DAFQKR] 1455
FAILURE CODE [DAJ0KK] 1460
FAILURE CODE [DAJ0KT] 1463
FAILURE CODE [DAJ0MC] 1464
FAILURE CODE [DAJ1KA] 1465
FAILURE CODE [DAJ2KK] 1467
FAILURE CODE [DAJ4KB] 1470
FAILURE CODE [DAJ4KZ] 1472
FAILURE CODE [DAJ5KX] 1474
FAILURE CODE [DAJ6KX] 1476
FAILURE CODE [DAJ9KQ] 1478
FAILURE CODE [DAJLKA] 1479
FAILURE CODE [DAJLKB] 1481
FAILURE CODE [DAJQKR] 1483
FAILURE CODE [DAJRKR] 1488
FAILURE CODE [DAJRMA] 1493
FAILURE CODE [DAZ9KQ] 1494
FAILURE CODE [DAZQKR] 1495
FAILURE CODE [DB2QKR] 1499
FAILURE CODE [DB2RKR] 1505
FAILURE CODE [DDAAL6] 1510
FAILURE CODE [DDB6L4] 1512
FAILURE CODE [DDD7KA] 1514
FAILURE CODE [DDD7KY] 1516
FAILURE CODE [DDE5MA] 1518
FAILURE CODE [DDE7KA] 1520
FAILURE CODE [DDE7KB] 1522
FAILURE CODE [DDK3KA] 1524
FAILURE CODE [DDK3KB] 1527
FAILURE CODE [DDK6KA] 1530
FAILURE CODE [DDK6KB] 1533
FAILURE CODE [DDNRLD] 1536
FAILURE CODE [DDS5L6] 1538
FAILURE CODE [DF10KA] 1540
FAILURE CODE [DF10KB] 1543
FAILURE CODE [DGH1KX] 1546
FAILURE CODE [DGR2KB] 1548
FAILURE CODE [DGR2KZ] 1550
FAILURE CODE [DHH1KX] 1552
FAILURE CODE [DHH1KY] 1554
FAILURE CODE [DHTCL6] 1556
FAILURE CODE [DJF1KA] 1558
FAILURE CODE [DK55KA] 1559
FAILURE CODE [DK55KY] 1562
FAILURE CODE [DK55L5] 1565
FAILURE CODE [DK5DKA] 1566
FAILURE CODE [DK5DKY] 1569
FAILURE CODE [DK5DL8] 1572
FAILURE CODE [DK5EKA] 1576
FAILURE CODE [DK5EKY] 1579
FAILURE CODE [DLM3KA] 1582
FAILURE CODE [DLM3LC] 1583
FAILURE CODE [DLT3KX] 1585
FAILURE CODE [DLT4KX] 1587
FAILURE CODE [DLT4L0] 1589
FAILURE CODE [DLT4LC] 1590
FAILURE CODE [DPQ1KR] 1592
FAILURE CODE [DPQ2KR] 1595
FAILURE CODE [DPQ3KR] 1598
FAILURE CODE [DSJ0KR] 1602
FAILURE CODE [DT22KB] 1607
FAILURE CODE [DV00KB] 1609
FAILURE CODE [DW26KA] 1610
FAILURE CODE [DW26KB] 1612
FAILURE CODE [DW26KY] 1614
FAILURE CODE [DW44KA] 1616
FAILURE CODE [DW44KB] 1618
FAILURE CODE [DW44KY] 1620
FAILURE CODE [DWM1KA] 1621
FAILURE CODE [DWM1KB] 1622
FAILURE CODE [DWM1KY] 1624
FAILURE CODE [DWN6KA] 1625
FAILURE CODE [DWN6KB] 1627
FAILURE CODE [DWN6KY] 1628
FAILURE CODE [DWN7KA] 1629
FAILURE CODE [DWN7KB] 1631
FAILURE CODE [DWN7KY] 1632
FAILURE CODE [DWN8KA] 1633
FAILURE CODE [DWN8KB] 1635
FAILURE CODE [DWN8KY] 1636
FAILURE CODE [DWPBKA] 1637
FAILURE CODE [DWPBKB] 1639
FAILURE CODE [DWPBKY] 1641
FAILURE CODE [DX19KA] 1643
FAILURE CODE [DX19KB] 1646
FAILURE CODE [DX19KY] 1648
FAILURE CODE [DX20KA] 1650
FAILURE CODE [DX20KB] 1652
FAILURE CODE [DX20KY] 1654
FAILURE CODE [DXH7KA] 1656
FAILURE CODE [DXH7KB] 1658
FAILURE CODE [DXH7KY] 1660
FAILURE CODE [DXH8KA] 1662
FAILURE CODE [DXH8KB] 1664
FAILURE CODE [DXH8KY] 1666
FAILURE CODE [DXHJKA] 1668
FAILURE CODE [DXHJKB] 1670
FAILURE CODE [DXHJKY] 1672
FAILURE CODE [DXHKKA] 1674
FAILURE CODE [DXHKKB] 1676
FAILURE CODE [DXHKKY] 1678
FAILURE CODE [H2K0KA] 1680
FAILURE CODE [H2K0KY] 1682
FAILURE CODE [J141N1] 1684
FAILURE CODE [LA00L3] 1685
FAILURE CODE [M100N1] 1686
FAILURE CODE [M400N1] 1687
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1688
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1688
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1694
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1697
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1700
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 1702
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 1705
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 1707
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 1709
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 1711
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 1714
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 1718
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 1720
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 1723
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 1726
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 1729
E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 1730
E-17 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 1733
E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 1738
E-19 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 1742
E-20 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP 1744
E-21 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 1745
E-22 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 1749
E-23 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 1750
E-24 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 1751
E-25 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 1752
E-26 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 1754
E-27 ALARM BUZZER DOES NOT SOUND 1755
E-28 ALARM BUZZER DOES NOT STOP SOUNDING 1756
E-29 WHEN THE SECONDARY HST TRAVEL SWITCH IS OPERATED, IT DOES NOT WORK OR WHEN THE SECONDARY HST PUMP DRIVE SWITCH IS NOT OPERATED, IT WORKS 1757
E-30 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH 1760
E-31 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED 1762
E-32 THE BOOM KICK-OUT DOES NOT WORK OR CANNOT BE RELEASED 1765
E-33 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED 1767
E-34 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 1770
E-35 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX TRACTION SWITCH IS TURNED ON 1772
E-36 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 1774
E-37 HORN DOES NOT SOUND 1776
E-38 HORN DOES NOT STOP SOUNDING 1779
E-39 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 1781
E-40 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 1783
E-41 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT 1787
E-42 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 1791
E-43 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 1793
E-44 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 1795
E-45 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT 1800
E-46 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT 1804
E-47 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT 1807
E-48 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT 1810
E-49 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 1814
E-50 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 1818
E-51 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 1822
E-52 FRONT WIPER DOES NOT OPERATE 1824
E-53 REAR WIPER DOES NOT OPERATE 1828
E-54 WINDOW WASHER DOES NOT OPERATE 1831
E-55 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1834
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1835
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1835
FAILURE MODE AND CAUSE TABLE 1836
H-1 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE 1850
H-2 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY) 1852
H-3 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY) 1853
H-4 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS LOW 1854
H-5 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE NORMALLY) 1857
H-6 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD NORMALLY) 1859
H-7 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1860
H-8 MACHINE DOES NOT TURN 1862
H-9 STEERING WHEEL IS HEAVY TO OPERATE 1863
H-10 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS 1864
H-11 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS 1865
H-12 WHEEL BRAKES DO NOT WORK OR ARE WEAK 1866
H-13 WHEEL BRAKES ARE NOT RELEASED OR DRAG 1868
H-14 PARKING BRAKE DOES NOT WORK OR IT IS WEAK 1869
H-15 PARKING BRAKE IS NOT RELEASED OR DRAGS 1870
H-16 BOOM DOES NOT RISE 1872
H-17 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE 1874
H-18 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 1876
H-19 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 1877
H-20 HYDRAULIC DRIFT OF BOOM IS LARGE 1879
H-21 BOOM MOVES UP AND DOWN DURING OPERATION 1880
H-22 BUCKET DOES NOT TILT BACK 1881
H-23 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 1883
H-24 BUCKET DECELERATES DURING TILT-BACK OPERATION 1885
H-25 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 1886
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE 1888
H-27 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) 1889
H-28 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE 1890
H-29 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1891
H-30 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 1892
H-31 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1894
H-32 E C S S (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 1895
H-33 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1896
H-34 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1898
TROUBLESHOOTING OF ENGINE (S-MODE) 1899
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1899
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1900
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1901
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1902
S-4 ENGINE STARTABILITY IS POOR 1904
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1906
S-6 ENGINE STOPS DURING OPERATION 1908
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1910
S-8 ENGINE LACKS POWER 1911
S-9 EXHAUST SMOKE IS BLACK 1913
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1915
S-11 OIL BECOMES CONTAMINATED QUICKLY 1916
S-12 FUEL CONSUMPTION IS EXCESSIVE 1917
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1918
S-14 OIL PRESSURE DROPS 1919
S-15 FUEL MIXES INTO ENGINE OIL 1921
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1922
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1923
S-18 UNUSUAL NOISE IS HEARD 1924
S-19 VIBRATION IS EXCESSIVE 1925
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1926
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1927
S-22 ACTIVE REGENERATION TAKES TIME 1928
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1929
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1930
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1932
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1933
50 DISASSEMBLY AND ASSEMBLY 1935
CONTENTS 1936
ABBREVIATION LIST 1940
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1946
HOW TO READ THIS MANUAL 1946
COATING MATERIALS LIST 1948
SPECIAL TOOLS LIST 1952
SKETCHES OF SPECIAL TOOLS 1973
ENGINE AND COOLING SYSTEM 1982
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1982
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1983
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1989
REMOVE AND INSTALL INJECTOR ASSEMBLY 1995
METHOD FOR REMOVING INJECTOR ASSEMBLY 1995
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2006
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2018
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2019
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2038
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2065
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2065
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2068
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2072
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2072
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2079
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2087
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2087
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2089
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 2091
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 2091
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 2093
REMOVE AND INSTALL ALTERNATOR BELT 2095
METHOD FOR REMOVING ALTERNATOR BELT 2095
METHOD FOR INSTALLING ALTERNATOR BELT 2100
REMOVE AND INSTALL ALTERNATOR ASSEMBLY 2104
METHOD FOR REMOVING ALTERNATOR ASSEMBLY 2104
METHOD FOR INSTALLING ALTERNATOR ASSEMBLY 2106
REMOVE AND INSTALL AUTOMATIC TENSIONER 2108
METHOD FOR REMOVING AUTOMATIC TENSIONER 2108
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2113
REMOVE AND INSTALL RADIATOR ASSEMBLY 2118
METHOD FOR REMOVING RADIATOR ASSEMBLY 2118
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2124
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2131
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2131
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2135
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2140
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2140
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2142
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2144
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2144
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2146
REMOVE AND INSTALL ENGINE ASSEMBLY 2149
METHOD FOR REMOVING ENGINE ASSEMBLY 2150
METHOD FOR INSTALLING ENGINE ASSEMBLY 2168
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2188
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2188
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2193
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2200
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2201
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2203
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2207
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2207
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2219
REMOVE AND INSTALL KDOC ASSEMBLY 2231
METHOD FOR REMOVING KDOC ASSEMBLY 2231
METHOD FOR INSTALLING KDOC ASSEMBLY 2238
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY 2248
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY 2249
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY 2261
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2272
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2272
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2276
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2282
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2282
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2286
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2291
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2292
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2299
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2307
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2307
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2309
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2312
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2312
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2313
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2320
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2320
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2321
REMOVE AND INSTALL SCR ASSEMBLY 2322
METHOD FOR REMOVING SCR ASSEMBLY 2322
METHOD FOR INSTALLING SCR ASSEMBLY 2331
REMOVE AND INSTALL KCCV ASSEMBLY 2343
METHOD FOR REMOVING KCCV ASSEMBLY 2343
METHOD FOR INSTALLING KCCV ASSEMBLY 2344
REMOVE AND INSTALL VGT ASSEMBLY 2347
METHOD FOR REMOVING VGT ASSEMBLY 2347
METHOD FOR INSTALLING VGT ASSEMBLY 2362
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2378
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2378
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2384
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2391
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2391
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2394
REMOVE AND INSTALL AdBlue/DEF PUMP 2397
METHOD FOR REMOVING AdBlue/DEF PUMP 2397
METHOD FOR INSTALLING AdBlue/DEF PUMP 2401
REMOVE AND INSTALL AdBlue/DEF HOSE 2406
METHOD FOR REMOVING AdBlue/DEF HOSE 2406
METHOD FOR INSTALLING AdBlue/DEF HOSE 2416
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2427
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2427
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2431
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2435
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2436
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2439
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2442
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2442
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2444
POWER TRAIN 2446
REMOVE AND INSTALL HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY 2446
METHOD FOR REMOVING HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY 2447
METHOD FOR INSTALLING HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY 2451
REMOVE AND INSTALL HST MOTOR1 ASSEMBLY 2455
METHOD FOR REMOVING HST MOTOR1 ASSEMBLY 2455
METHOD FOR INSTALLING HST MOTOR1 ASSEMBLY 2457
REMOVE AND INSTALL HST MOTOR2 ASSEMBLY 2460
METHOD FOR REMOVING HST MOTOR2 ASSEMBLY 2460
METHOD FOR INSTALLING HST MOTOR2 ASSEMBLY 2462
REMOVE AND INSTALL TRANSFER ASSEMBLY 2464
METHOD FOR REMOVING TRANSFER ASSEMBLY 2465
METHOD FOR INSTALLING TRANSFER ASSEMBLY 2472
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY 2479
METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY 2480
METHOD FOR ASSEMBLING TRANSFER ASSEMBLY 2495
REMOVE AND INSTALL FRONT AXLE ASSEMBLY 2514
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 2514
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 2516
REMOVE AND INSTALL REAR AXLE ASSEMBLY 2518
METHOD FOR REMOVING REAR AXLE ASSEMBLY 2518
METHOD FOR INSTALLING REAR AXLE ASSEMBLY 2520
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY 2523
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY 2524
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY 2528
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY 2536
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY 2537
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY 2551
UNDERCARRIAGE AND FRAME 2573
REMOVE AND INSTALL CENTER HINGE PIN 2573
METHOD FOR REMOVING CENTER HINGE PIN 2574
METHOD FOR INSTALLING CENTER HINGE PIN 2582
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2594
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2594
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2608
HYDRAULIC SYSTEM 2619
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2619
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2620
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2626
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2632
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2632
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2637
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY 2642
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 2643
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 2646
WORK EQUIPMENT 2653
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2653
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2654
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2658
CAB AND ITS ATTACHMENTS 2669
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2669
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2670
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2682
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2695
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2695
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2696
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2705
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2705
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2711
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 2718
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 2718
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 2718
REMOVE AND INSTALL SEAT BELT 2720
METHOD FOR REMOVING SEAT BELT 2720
METHOD FOR INSTALLING SEAT BELT 2720
ELECTRICAL SYSTEM 2722
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2722
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2722
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2726
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 2731
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY 2731
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY 2733
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY 2735
METHOD FOR REMOVING AIR CONDITIONER CONTROLLER ASSEMBLY 2735
METHOD FOR INSTALLING AIR CONDITIONER CONTROLLER ASSEMBLY 2736
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 2738
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 2738
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 2741
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2743
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2743
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2746
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2749
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2749
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2750
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2752
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2752
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2753
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2755
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2755
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2758
REMOVE AND INSTALL SCR OUTLET NOx SENSOR 2762
METHOD FOR REMOVING SCR OUTLET NOx SENSOR 2762
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR 2765
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2769
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2769
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2770
60 MAINTENANCE STANDARD 2771
CONTENTS 2772
ABBREVIATION LIST 2773
ENGINE AND COOLING SYSTEM 2779
MAINTENANCE STANDARD OF ENGINE MOUNT 2779
MAINTENANCE STANDARD OF DAMPER 2780
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2781
POWER TRAIN 2785
MAINTENANCE STANDARD OF DRIVE SHAFT 2785
MAINTENANCE STANDARD OF TRANSFER 2786
MAINTENANCE STANDARD OF TRANSFER MOUNT 2795
MAINTENANCE STANDARD OF FRONT AXLE 2796
MAINTENANCE STANDARD OF REAR AXLE 2797
MAINTENANCE STANDARD OF FRONT TORQUE PROPORTIONING DIFFERENTIAL 2798
MAINTENANCE STANDARD OF REAR TORQUE PROPORTIONING DIFFERENTIAL 2800
MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL 2802
MAINTENANCE STANDARD OF FRONT FINAL DRIVE 2804
MAINTENANCE STANDARD OF REAR FINAL DRIVE 2806
STEERING SYSTEM 2808
MAINTENANCE STANDARD OF STEERING COLUMN 2808
MAINTENANCE STANDARD OF PRIORITY VALVE 2809
MAINTENANCE STANDARD OF STEERING CYLINDER 2810
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE 2812
BRAKE SYSTEM 2813
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE 2813
MAINTENANCE STANDARD OF SLACK ADJUSTER 2814
MAINTENANCE STANDARD OF FRONT BRAKE 2815
MAINTENANCE STANDARD OF REAR BRAKE 2816
MAINTENANCE STANDARD OF PARKING BRAKE 2817
UNDERCARRIAGE AND FRAME 2818
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 2818
HYDRAULIC SYSTEM 2823
MAINTENANCE STANDARD OF HYDRAULIC TANK 2823
MAINTENANCE STANDARD OF STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP 2824
MAINTENANCE STANDARD OF CONTROL VALVE 2826
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE 2829
MAINTENANCE STANDARD OF ATTACHMENT EPC SOLENOID VALVE 2831
WORK EQUIPMENT 2832
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2832
MAINTENANCE STANDARD OF BUCKET 2835
MAINTENANCE STANDARD OF LIFT CYLINDER 2836
MAINTENANCE STANDARD OF BUCKET CYLINDER 2837
MAINTENANCE STANDARD OF COUPLER PLUNGER 2838
CAB AND ITS ATTACHMENTS 2839
MAINTENANCE STANDARD OF CAB MOUNT 2839
80 APPENDIX 2841
CONTENTS 2842
ABBREVIATION LIST 2844
AIR CONDITIONER SYSTEM 2850
PRECAUTIONS FOR REFRIGERANT 2850
AIR CONDITIONER COMPONENT 2851
SPECIFICATIONS OF AIR CONDITIONER 2853
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2854
OUTLINE OF REFRIGERATION CYCLE 2855
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2857
AIR CONDITIONER UNIT 2857
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2857
FUNCTION OF AIR CONDITIONER UNIT 2858
COMPONENT PARTS OF AIR CONDITIONER UNIT 2859
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2859
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2859
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT 2860
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT 2860
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 2860
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2860
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2860
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2860
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2861
FUNCTION OF DUAL PRESSURE SWITCH 2861
AIR CONDITIONER CONTROLLER 2862
STRUCTURE OF AIR CONDITIONER CONTROLLER 2862
COMPRESSOR 2863
STRUCTURE OF COMPRESSOR 2863
SPECIFICATIONS OF COMPRESSOR 2863
FUNCTION OF COMPRESSOR 2863
CONDENSER 2864
STRUCTURE OF CONDENSER 2864
SPECIFICATIONS OF CONDENSER 2864
FUNCTION OF CONDENSER 2864
RECEIVER DRIER 2865
STRUCTURE OF RECEIVER DRIER 2865
SPECIFICATIONS OF RECEIVER DRIER 2865
FUNCTION OF RECEIVER DRIER 2865
SENSORS FOR AIR CONDITIONER SYSTEM 2866
FUNCTION OF SUNLIGHT SENSOR 2866
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2866
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2867
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2869
AIR CONDITIONER SYSTEM DIAGRAM 2872
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2873
FUNCTION OF AIR CONDITIONER CONTROLLER 2874
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2875
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2881
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2882
CHECK TEMPERATURE CONTROL FUNCTION 2883
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION 2883
TEST VENT (MODE) CHANGEOVER 2885
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2885
TESTING FRESH/RECIRC AIR CHANGEOVER 2887
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2887
TEST EVAPORATOR TEMPERATURE SENSOR 2889
TEST RELAYS 2891
METHOD FOR TESTING RELAYS 2891
AIR CONDITIONER TROUBLESHOOTING CHART 1 2893
AIR CONDITIONER TROUBLESHOOTING CHART 2 2894
FAILURE CODE [879AKA] 2897
FAILURE CODE [879AKB] 2899
FAILURE CODE [879BKA] 2901
FAILURE CODE [879BKB] 2903
FAILURE CODE [879CKA] 2905
FAILURE CODE [879CKB] 2907
FAILURE CODE [879DKZ] 2909
FAILURE CODE [879EMC] 2911
FAILURE CODE [879FMC] 2912
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2913
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2916
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2919
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2923
TROUBLESHOOTING USING GAUGE PRESSURE 2925
CONNECTION OF SERVICE TOOL 2928
METHOD FOR CONNECTING SERVICE TOOL 2929
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2930
HANDLE COMPRESSOR OIL 2932
90 CIRCUIT DIAGRAMS 2935
CONTENTS 2936
ABBREVIATION LIST 2937
HYDRAULIC CIRCUIT DIAGRAM 2943
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2943
HYDRAULIC CIRCUIT DIAGRAM 0
ELECTRICAL CIRCUIT DIAGRAM 2947
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2947
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/10) 0
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/9) 0
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/9) 0
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/9) 0
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/9) 0
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/9) 0
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/9) 0
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/9) 0
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/9) 0
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/9) 0
INDEX 2951
VENAM32500_WA200-8_A4 2969
Letzte Seite pdf 2968

DESCRIPTION:

Komatsu WA200-8 Wheel Loader Shop Manual VENBM32500 – PDF DOWNLOAD 

SERIAL NUMBERS

H80051 and up
85001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
REMARK
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

S.V 31/12/24