Komatsu WA200-8E0 Wheel Loader Shop Manual SEN06859-07 PDF

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Komatsu WA200-8E0 Wheel Loader Shop Manual SEN06859-07 – PDF DOWNLOAD

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Komatsu WA200-8E0 Wheel Loader Shop Manual SEN06859-07 – PDF DOWNLOAD 

Language : English
Pages : 3262
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA200-8E0 Wheel Loader Shop Manual SEN06859-07 – PDF DOWNLOAD 

SERIAL NUMBERS 95001 and up

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 22
How to Read the Shop Manual 22
Safety Notice for Operation 24
Precautions to Prevent Fire 32
Procedures If Fire Occurs 34
Precautions for Disposing of Waste Materials 35
Procedures for Exhaust Gas Regulations 36
Precautions for DEF 37
General Character and Precautions for Handling 37
Precautions for Adding 37
Precautions for Storage 37
Precautions for Fire Hazard and Leakage 37
Other Precautions 37
Store DEF 38
Precautions When You Handle Hydraulic Equipment 39
Precautions When You Disconnect and Connect Pipings 42
Precautions When You Handle Electrical Equipment 49
Precautions When You Handle Fuel System Equipment 51
Precautions When You Handle Intake System Equipment 52
Practical Use of KOMTRAX 53
Disconnect and Connect Push-Pull Type Coupler 54
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 54
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 56
Precautions for Disconnection and Connection of Connectors 58
How to Disconnect and Connect Deutsch Connector 62
How to Disconnect and Connect Slide Lock Type Connector 63
How to Disconnect and Connect Connector with Lock to Pull 65
How to Disconnect and Connect Connector with Lock to Push 66
How to Disconnect and Connect Connector with Housing to Rotate 68
How to Read the Codes for Electric Cable 69
Explanation of Terms for Maintenance Standard 73
Standard Tightening Torque Table 76
Conversion Table 83
Abbreviation List 88
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: WA200-8E0 93
Specifications 95
Specification: WA200-8E0 95
Weight Table 100
Weight Table: WA200-8E0 100
Fuel, Coolant, Lubricants (for European Union and Turkey) 102
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 102
10 Structure and Function 105
Table of Contents 106
Urea SCR System 110
Layout Drawing of Urea SCR System 110
Urea SCR System Diagram 112
Function of Urea SCR System 113
Function of DEF System 113
Inducement Strategy 116
Component Parts of Urea SCR System 124
SCR Assembly 125
DEF Tank 127
DEF Pump 129
DEF Injector 130
DEF Hose 131
DEF Tank Heating Valve 132
Boot-up System 133
Layout Drawing of Boot-up System 133
System Operating Lamp System 135
System Diagram of System Operating Lamp System 135
Function of Operation Lamp System 135
Battery Disconnect Switch 136
Function of Battery Disconnect Switch 136
Preheating System 137
System Diagram of Preheating System 137
Function of Automatic Preheating System 137
Operation of Automatic Preheating System 137
Function of Manual Preheating System 138
Operation of Manual Preheating System 138
Engine System 139
Layout Drawing of Engine System 139
Function of Engine System 140
Engine Control System 141
System Diagram of Engine Control 141
Function of Engine Control System 143
Operation of Engine Control System 146
Automatic Idle Stop System 148
Function of Automatic Idle Stop System 148
Component Parts of Engine System 149
Damper 149
Turbocharger 150
Crankcase Ventilation System 153
Impactor (Filterless) 154
Exhaust Throttle Valve 155
KDPF 156
Cooling System 160
Layout Drawing of Cooling System 160
Specifications of Cooling System 161
Cooling Fan Control System 162
System Diagram of Cooling Fan Control System 162
Function of Cooling Fan Control System 163
Component Parts of Cooling System 167
Cooling Fan Motor 167
Hydraulic Oil Cooler Bypass Valve 177
Control System 178
Layout Drawing of Control System 178
Machine Monitor System 180
System Diagram of Machine Monitor System 180
Function of Machine Monitor System 180
Rearview Monitor System 182
System Diagram of Rearview Monitor System 182
Function of Rearview Monitor System 182
KOMTRAX System 183
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 183
Function of KOMTRAX System (Machine with Gateway Function Controller) 183
Component Parts of Control System 184
Machine Monitor 184
Switch Panel 202
Rearview Monitor 203
Rearview Camera 205
Gateway Function Controller 206
Communication Terminal 209
Monitor Controller 211
HST Controller 216
CAN Terminating Resistor 221
Engine Controller 222
Accelerator Pedal 229
Hydraulic System 231
Layout Drawing of Hydraulic System 231
Component Parts of Hydraulic System 232
Hydraulic Tank 232
Hydraulic Oil Filter 234
Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump 235
Control Valve 237
Power Train System 258
Layout Drawing of Power Train System 258
Operation of Power Train System 260
Directional Selector Switch Control Function 261
HST Control System 263
System Diagram of HST Control System 263
Engine Overrun Prevention Function 264
Neutralizer Function 264
HST Charge System 265
System Diagram of HST Charge System 265
Function of HST Charge System 265
HST Pump Control System 266
System Diagram of HST Pump Control System 266
Directional Selection Function 266
Inching Control Function 266
Travel Speed Adjustment Function (at Low Speed) 267
HST Controller Gear Shift Control Function 268
Gear Shift Function 268
Gear Shift Display Function 270
Travel Speed Adjustment Function 270
Transfer Clutch Control Function 271
HST System Protection Function 272
Direction Protection Function 272
HST Motor 1 Overrun Prevention Function 1 272
HST Motor 1 Overrun Prevention Function 2 273
Travel Speed Limitation Function 273
Komatsu Traction Control System (KTCS) 274
Komatsu Traction Control System (KTCS) Diagram 274
Function of Komatsu Traction Control System (KTCS) 275
Component Parts of Power Train System 279
Drive Shaft 279
HST Pump 281
HST Charge Pump 289
HST Motor 291
Transfer 300
Axle 308
Torque Proportioning Differential 310
Limited Slip Differential 314
Final Drive 318
Combination Switch 320
Work Equipment System 324
Layout Drawing of Work Equipment System 324
Work Equipment Control System 326
Work Equipment Lever Operation Function 326
Work Equipment Lock System 327
Work Equipment Lock System Diagram (Applicable Machine: 95001 to 95033) 327
Work Equipment Lock System Diagram (Applicable Machine: 95034 and Up) 327
Function of Work Equipment Lock System 328
Bucket Positioner System 329
Bucket Positioner System Diagram 329
Function of Bucket Positioner System 329
Operation of Bucket Positioner System 330
Boom Kick-out System 332
System Drawing of Boom Kick-out System 332
Function of Boom Kick-out System 332
Operation of Boom Kick-out System 333
ECSS 335
ECSS Diagram 335
Function of ECSS 335
Operation of ECSS 335
Component Parts of Work Equipment System 337
Work Equipment Lock Solenoid Valve 337
Attachment EPC Solenoid Valve 338
Pilot Circuit Accumulator 339
ECSS Circuit Accumulator 340
Multifunction Mono-Lever 341
Multifunction Mono-Lever PPC Valve 343
Quick Coupler Solenoid Valve 348
Steering System 349
Layout Drawing of Steering System 349
Steering Column 350
Structure of Steering Column 350
Component Parts of Steering System 351
Priority Valve 351
Orbitrol Valve 354
Cushion Valve 361
2-Way Restrictor Valve 363
Secondary Steering Valve 364
Brake System 367
Layout Drawing of Brake System 367
Parking Brake Control System 369
System Diagram of Parking Brake Control System 369
Operation of Parking Brake Control System 369
Component Parts of Brake System 372
Brake Circuit Accumulator Charge Valve 372
Parking Brake Solenoid Valve 376
Brake Circuit Accumulator 378
Brake Valve 380
Slack Adjuster 384
Brake 386
Parking Brake 389
Parking Brake Cylinder 391
Auto-Greasing System 392
Layout Drawing of Auto-Greasing System 392
Specifications of Auto-Greasing System 394
Function of Auto-Greasing System 396
Auto-Greasing System 397
Auto-Greasing Pump 397
Undercarriage and Frame 398
Frame, Axle Mount and Center Hinge Pin 398
Structure of Frame, Axle Mount and Center Hinge Pin 398
Function of Frame, Axle Mount and Center Hinge Pin 399
Tires 401
Features of Radial Tire When Compared with Bias Tire 401
Structure of Radial Tire 401
Function of Radial Tire 402
Structure of Bias Tire 402
Function of Bias Tire 402
Work Equipment 403
Structure of Work Equipment 403
Structure of Bucket 404
CAB Related Parts 405
ROPS CAB 405
Structure of ROPS CAB 405
Function of ROPS CAB 405
CAB Mount 406
Structure of CAB Mount 406
Function of CAB Mount 406
20 Standard Value Table 407
Table of Contents 408
Standard Value Table for Engine 409
Standard Value Table for Engine: WA200-8E0 409
Standard Value Table for Machine 414
Standard Value Table for Machine: WA200-8E0 414
Machine Posture and Procedures to Measure Performance 426
30 Testing and Adjusting 429
Table of Contents 430
Precautions Before Work 434
Related Information on Testing and Adjusting 435
Differences In Machine Monitor Symbols 435
Tools for Testing and Adjusting 436
Engine and Cooling System 445
Examine Engine Speed 445
How to Examine Engine Speed 445
Examine Boost Pressure 449
How to Examine Boost Pressure on Machine Monitor 449
How to Examine Boost Pressure by Testing Tool 450
Examine Exhaust Gas Temperature 452
How to Examine Exhaust Gas Temperature 452
Examine Exhaust Gas Color 454
How to Examine Exhaust Gas Color with the Handy Smoke Checker 454
How to Examine Exhaust Gas Color with Smoke Meter 456
Examine and Adjust Valve Clearance 459
How to Examine Valve Clearance 459
How to Adjust Valve Clearance 460
Examine Compression Pressure 462
How to Examine Compression Pressure 462
Examine Blowby Pressure 467
How to Examine Blowby Pressure 467
Examine Engine Oil Pressure 469
How to Examine Engine Oil Pressure 469
Examine Fuel Pressure 470
How to Examine Fuel Pressure 471
Examine Fuel Discharge, Return and Leakage 475
How to Examine Fuel Discharge, Return, and Leakage 476
Bleed Air from Fuel System 481
How to Bleed Air from Fuel System 481
Examine Fuel Circuit for Leakage 483
How to Examine Fuel System for Leakage 483
Handle Cylinder Cut-out Mode Operation 485
Handle No-Injection Cranking Operation 486
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 487
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 487
Examine Installed Condition of Cylinder Heads and Manifolds 488
How to Examine Installed Condition of Cylinder Heads and Manifolds 488
Examine Engine Piping for Damage and Looseness 489
How to Examine Engine Piping for Damage and Looseness 489
Examine and Adjust Air Conditioner Compressor Belt Tension 490
How to Examine Air Conditioner Compressor Belt 490
How to Adjust Air Conditioner Compressor Belt 490
Examine Alternator Belt 492
How to Examine Alternator Belt 492
Examine Automatic Tensioner 494
How to Examine Automatic Tensioner 494
Write Correction for Ash in Soot Accumulation to Engine Controller 497
How to Write Correction for Ash in Soot Accumulation to Engine Controller 497
Examine SCR Related Functions 498
Examine DEF Pump Raised Pressure 502
Examine Injection Volume from DEF Injector 505
Examine DEF Line Heater Relay 1 511
Examine DEF Line Heater Relay 2 515
Examine DEF Pump Heater Relay 519
Examine DEF Tank Heater Valve 523
Examine SCR Denitration Efficiency 527
Clean DEF Tank 530
How to Clean DEF Tank 530
Clean DEF Pump 535
How to Clean DEF Pump 535
Power Train 541
Examine and Adjust HST Oil Pressure 541
How to Examine HST Oil Pressure 541
How to Adjust HST Oil Pressure 544
Examine the Control Pressure of Transfer Clutch 546
How to Examine the Control Pressure of Transfer Clutch 546
Examine Drive Shaft for Looseness, Backlash, and Damage 548
How to Examine Drive Shaft for Looseness, Backlash, and Damage 548
Steering System 549
Examine Steering Wheel 549
How to Examine Steering Wheel 549
Examine and Adjust Steering Circuit Oil Pressure 551
How to Examine Steering Circuit Oil Pressure 551
How to Adjust Steering Circuit Oil Pressure 552
Bleed Air from Steering Cylinder Circuit 554
How to Bleed Air from Steering Cylinder Circuit 554
Brake System 555
Release Remained Pressure in Brake Accumulator Circuit 555
How to Release Remained Pressure in Brake Accumulator Circuit 555
Examine Wheel Brake Oil Pressure 556
How to Examine Wheel Brake Oil Pressure 556
Examine and Adjust Brake Accumulator Charge Pressure 558
How to Examine Brake Accumulator Charge Pressure 558
How to Adjust Brake Accumulator Charge Pressure 559
Bleed Air from Brake Circuit 560
How to Bleed Air from Brake Circuit 560
Examine Brake Performance 562
How to Examine Brake Performance 562
Examine Brake Pedal 563
How to Examine Brake Pedal 563
Examine and Adjust Brake Pedal and Linkage 564
How to Examine Brake Pedal and Linkage 564
How to Adjust Brake Pedal and Linkage 564
Examine Pressure Decrease of Wheel Brake 565
How to Examine Pressure Decrease of Wheel Brake 566
Examine Wear of Wheel Brake Disc 568
How to Examine Wear of Wheel Brake Disc 568
Examine Parking Brake Oil Pressure 570
How to Examine Parking Brake Oil Pressure 570
Examine Parking Brake Performance 572
How to Examine Parking Brake Performance 572
Release Parking Brake Manually 573
How to Release Parking Brake Manually 573
Hydraulic System 574
Release Remained Pressure from Work Equipment Circuit 574
How to Release Remained Pressure from Work Equipment Circuit 574
Examine and Adjust Work Equipment Oil Pressure 576
How to Examine Work Equipment Oil Pressure 576
How to Adjust Work Equipment Oil Pressure 577
Examine Work Equipment PPC Oil Pressure 579
How to Examine Work Equipment PPC Oil Pressure 579
Bleed Air from Work Equipment PPC Circuit 581
How to Bleed Remaining Pressure from Work Equipment PPC Circuit 581
Examine Cooling Fan Speed 582
How to Examine Cooling Fan Speed 582
Examine Cooling Fan Circuit Oil Pressure 583
How to Examine Cooling Fan Circuit Oil Pressure 583
Bleed Air from Cooling Fan Circuit 585
How to Bleed Air from Cooling Fan Circuit 585
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas 587
How to Examine ECSS Accumulator Nitrogen Gas Pressure 587
How to Charge ECSS Accumulator with Nitrogen Gas 589
Work Equipment 592
Examine and Adjust Bucket Positioner 592
How to Examine Bucket Positioner 592
How to Adjust Bucket Positioner 592
CAB Related Parts 594
Examine Directional Lever 594
How to Examine Directional Lever 594
Examine Multifunction Mono-Lever 595
How to Examine Multifunction Mono-Lever 595
Examine Accelerator Pedal 597
How to Examine Accelerator Pedal 597
Adjust Play of Operator Seat 599
How to Adjust Play of Operator Seat 599
Electrical System 600
Set and Adjust Each Equipment 600
Set and Operate Machine Monitor 602
Operator Mode 606
Function to Show Technician Identification Status Screen 606
Function to Show Operator Identification Input Screen 606
Examine Function by LCD (Liquid Crystal Display) 607
Examine Function of Service Meter and Odometer 608
How to Set Usage Limitation and Change Maintenance Password 608
Service Mode 612
How to Operate Service Mode 612
How to See Pre-defined Monitoring Information 614
How to Examine Self-Define Monitor Information 620
Abnormality Record Menu 632
How to See Maintenance Record 637
Maintenance Mode Setting 639
How to Set Phone Number Entry 644
Default Menu 646
Diagnostic Tests Menu 660
Adjustment Menu 671
No-Injection Cranking Operation 690
KOMTRAX Settings Menu 693
How to Show Service Message 695
How to Start Up KOMTRAX System 697
How to Stop Use of KOMTRAX System 703
Adjust Rearview Camera Angle 705
How to Adjust Rearview Camera Angle 705
Set Region of Bluetooth(R) Compatible Radio 707
How to Set Region of Bluetooth(R) Compatible Radio 707
Handle Voltage Circuit of Engine Controller 709
Handle Battery Disconnect Switch 710
Examine Diodes 711
How to Examine Diodes by Digital Tester 711
How to Examine Diodes by Analog Tester 711
Pm Clinic 712
Pm Clinic Service 712
Pm Clinic Check Sheet: WA200-8E0 714
40 Troubleshooting 723
Table of Contents 724
Precautions Before Work 735
Related Information to Troubleshooting 736
Precautions for Troubleshooting 736
General Troubleshooting Points 737
Troubleshooting Points for Urea SCR System 738
Sequence of Events in Troubleshooting 749
Checks Before Troubleshooting 751
Inspection Procedure Before Troubleshooting 753
Walk-Around Check 753
Test in Accordance with Testing Procedure 755
Examine Fuel Level and Type 755
Examine for Impure Ingredient in Fuel 755
Examine DEF Level and Type 756
Examine Fuel Prefilter 756
Examine Fuel Main Filter 758
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 760
Examine Coolant Level (Reservoir Tank) 761
Examine Air Cleaner Clogging 762
Clean Outer Element 763
Replace Element 765
Examine Hydraulic Oil Level 767
Examine Hydraulic Oil Filter 769
Examine the Oil Level in the Transfer Case 770
Examine Oil Level in Front Axle Case 771
Examine Oil Level in Rear Axle Case 772
Bleed Air from Fuel System 773
Bleed Air from Hydraulic System 773
How to Examine Electric Equipment 773
Preparation for Troubleshooting of Electrical System 780
Procedure for Troubleshooting 788
Symptom and Troubleshooting Numbers 790
Information Shown in Troubleshooting Table 794
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 796
Connectors List 799
Connector Layout 809
Connector Contact Connection Table 819
T-Branch Box and T-Branch Adapter Table 866
Fuse Location Table 872
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 876
Prepare Troubleshoot Machine Monitor 880
Procedure to Make Harness Checker on Machine Monitor LCD Unit 882
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 888
Failure Code Table 890
Troubleshooting by Failure Code (Display of Code) 909
Failure Code [2F00MA] 909
Failure Code [2F00MB] 912
Failure Code [2G42ZG] 914
Failure Code [2G43ZG] 916
Failure Code [6091NX] 918
Failure Code [7RHYKA] 920
Failure Code [7RHYKB] 922
Failure Code [7RHYKY] 924
Failure Code [879AKA] 926
Failure Code [879AKB] 928
Failure Code [879BKA] 930
Failure Code [879BKB] 932
Failure Code [879CKA] 934
Failure Code [879CKB] 936
Failure Code [879DKZ] 938
Failure Code [879EMC] 940
Failure Code [879FMC] 941
Failure Code [989FN1] 942
Failure Code [989L00] 943
Failure Code [989M00] 944
Failure Code [989N00] 945
Failure Code [A1U0N3] 946
Failure Code [A1U0N4] 948
Failure Code [AB00KE] 950
Failure Code [AB00KY] 952
Failure Code [AQ10MB] 954
Failure Code [AS00R2] 956
Failure Code [AS00R3] 957
Failure Code [AS00R4] 958
Failure Code [AS00R5] 959
Failure Code [AS00R6] 960
Failure Code [AS00ZK] 961
Failure Code [AS10KM] 962
Failure Code [AS10NR] 963
Failure Code [AS10NT] 964
Failure Code [B@BAZG] 965
Failure Code [B@BCNS] 966
Failure Code [B@BCQA] 967
Failure Code [B@BCZK] 969
Failure Code [B@C6NS] 971
Failure Code [B@CRNS] 973
Failure Code [CA115] 974
Failure Code [CA122] 975
Failure Code [CA123] 977
Failure Code [CA131] 979
Failure Code [CA132] 981
Failure Code [CA144] 984
Failure Code [CA145] 986
Failure Code [CA153] 988
Failure Code [CA154] 990
Failure Code [CA187] 992
Failure Code [CA227] 994
Failure Code [CA234] 996
Failure Code [CA238] 997
Failure Code [CA239] 998
Failure Code [CA249] 999
Failure Code [CA256] 1001
Failure Code [CA271] 1003
Failure Code [CA272] 1005
Failure Code [CA322] 1006
Failure Code [CA324] 1008
Failure Code [CA331] 1010
Failure Code [CA332] 1012
Failure Code [CA343] 1014
Failure Code [CA351] 1015
Failure Code [CA352] 1016
Failure Code [CA386] 1018
Failure Code [CA428] 1019
Failure Code [CA429] 1021
Failure Code [CA431] 1023
Failure Code [CA432] 1026
Failure Code [CA435] 1030
Failure Code [CA441] 1032
Failure Code [CA442] 1034
Failure Code [CA451] 1035
Failure Code [CA452] 1037
Failure Code [CA488] 1039
Failure Code [CA515] 1040
Failure Code [CA516] 1042
Failure Code [CA553] 1044
Failure Code [CA555] 1045
Failure Code [CA556] 1046
Failure Code [CA559] 1047
Failure Code [CA689] 1050
Failure Code [CA691] 1053
Failure Code [CA692] 1055
Failure Code [CA697] 1057
Failure Code [CA698] 1058
Failure Code [CA731] 1059
Failure Code [CA741] 1061
Failure Code [CA742] 1063
Failure Code [CA743] 1065
Failure Code [CA778] 1066
Failure Code [CA1117] 1071
Failure Code [CA1664] 1073
Failure Code [CA1669] 1076
Failure Code [CA1673] 1077
Failure Code [CA1677] 1078
Failure Code [CA1678] 1079
Failure Code [CA1682] 1080
Failure Code [CA1683] 1085
Failure Code [CA1684] 1087
Failure Code [CA1686] 1089
Failure Code [CA1695] 1090
Failure Code [CA1696] 1091
Failure Code [CA1712] 1094
Failure Code [CA1713] 1097
Failure Code [CA1714] 1099
Failure Code [CA1715] 1100
Failure Code [CA1776] 1101
Failure Code [CA1777] 1104
Failure Code [CA1843] 1107
Failure Code [CA1844] 1109
Failure Code [CA1879] 1112
Failure Code [CA1881] 1114
Failure Code [CA1883] 1116
Failure Code [CA1885] 1119
Failure Code [CA1887] 1121
Failure Code [CA1921] 1123
Failure Code [CA1922] 1126
Failure Code [CA1942] 1131
Failure Code [CA1993] 1132
Failure Code [CA2185] 1135
Failure Code [CA2186] 1137
Failure Code [CA2311] 1139
Failure Code [CA2373] 1140
Failure Code [CA2374] 1142
Failure Code [CA2554] 1144
Failure Code [CA2555] 1146
Failure Code [CA2556] 1148
Failure Code [CA2639] 1150
Failure Code [CA2771] 1152
Failure Code [CA2973] 1156
Failure Code [CA2976] 1157
Failure Code [CA3133] 1159
Failure Code [CA3134] 1161
Failure Code [CA3135] 1163
Failure Code [CA3142] 1166
Failure Code [CA3143] 1167
Failure Code [CA3144] 1168
Failure Code [CA3146] 1171
Failure Code [CA3147] 1172
Failure Code [CA3148] 1173
Failure Code [CA3151] 1176
Failure Code [CA3165] 1184
Failure Code [CA3229] 1186
Failure Code [CA3231] 1188
Failure Code [CA3232] 1190
Failure Code [CA3235] 1194
Failure Code [CA3239] 1196
Failure Code [CA3241] 1199
Failure Code [CA3242] 1202
Failure Code [CA3251] 1205
Failure Code [CA3253] 1207
Failure Code [CA3254] 1210
Failure Code [CA3255] 1212
Failure Code [CA3256] 1216
Failure Code [CA3311] 1218
Failure Code [CA3312] 1220
Failure Code [CA3313] 1223
Failure Code [CA3314] 1224
Failure Code [CA3315] 1225
Failure Code [CA3316] 1228
Failure Code [CA3317] 1229
Failure Code [CA3318] 1230
Failure Code [CA3319] 1233
Failure Code [CA3321] 1234
Failure Code [CA3322] 1236
Failure Code [CA3497] 1239
Failure Code [CA3498] 1240
Failure Code [CA3545] 1241
Failure Code [CA3547] 1243
Failure Code [CA3558] 1244
Failure Code [CA3559] 1246
Failure Code [CA3562] 1248
Failure Code [CA3563] 1250
Failure Code [CA3567] 1253
Failure Code [CA3568] 1257
Failure Code [CA3571] 1263
Failure Code [CA3572] 1265
Failure Code [CA3574] 1267
Failure Code [CA3575] 1270
Failure Code [CA3577] 1272
Failure Code [CA3578] 1274
Failure Code [CA3583] 1276
Failure Code [CA3596] 1278
Failure Code [CA3649] 1282
Failure Code [CA3681] 1284
Failure Code [CA3682] 1289
Failure Code [CA3713] 1294
Failure Code [CA3717] 1297
Failure Code [CA3718] 1298
Failure Code [CA3725] 1299
Failure Code [CA3741] 1302
Failure Code [CA3748] 1303
Failure Code [CA3866] 1305
Failure Code [CA3868] 1308
Failure Code [CA4151] 1312
Failure Code [CA4152] 1316
Failure Code [CA4155] 1320
Failure Code [CA4156] 1323
Failure Code [CA4157] 1326
Failure Code [CA4158] 1328
Failure Code [CA4159] 1329
Failure Code [CA4161] 1330
Failure Code [CA4162] 1333
Failure Code [CA4163] 1336
Failure Code [CA4164] 1338
Failure Code [CA4165] 1340
Failure Code [CA4166] 1342
Failure Code [CA4168] 1343
Failure Code [CA4169] 1346
Failure Code [CA4171] 1348
Failure Code [CA4249] 1350
Failure Code [CA4251] 1352
Failure Code [CA4259] 1354
Failure Code [CA4261] 1357
Failure Code [CA4277] 1360
Failure Code [CA4459] 1364
Failure Code [CA4461] 1366
Failure Code [CA4731] 1369
Failure Code [CA4732] 1370
Failure Code [CA4739] 1371
Failure Code [CA4768] 1372
Failure Code [CA4769] 1374
Failure Code [CA4842] 1377
Failure Code [CA4952] 1380
Failure Code [CA5115] 1382
Failure Code [CA5179] 1385
Failure Code [CA5181] 1387
Failure Code [CA5271] 1389
Failure Code [CA5272] 1391
Failure Code [CA5273] 1393
Failure Code [CA5274] 1394
Failure Code [CA5275] 1396
Failure Code [CA5276] 1398
Failure Code [CA5383] 1400
Failure Code [CA5631] 1402
Failure Code [CA5632] 1404
Failure Code [CA5655] 1406
Failure Code [CA5689] 1412
Failure Code [CA5715] 1414
Failure Code [CA5716] 1417
Failure Code [CA5838] 1420
Failure Code [CA5864] 1422
Failure Code [CA5865] 1424
Failure Code [CA5938] 1426
Failure Code [CA6771] 1428
Failure Code [D103KA] 1433
Failure Code [D103KB] 1435
Failure Code [D103KY] 1437
Failure Code [D103MC] 1439
Failure Code [D110L4] 1441
Failure Code [D160KA] 1443
Failure Code [D160KY] 1445
Failure Code [D191KA] 1446
Failure Code [D191KB] 1448
Failure Code [D191KY] 1450
Failure Code [D192KA] 1451
Failure Code [D192KB] 1452
Failure Code [D192KY] 1453
Failure Code [D19JKZ] 1454
Failure Code [D1B0KA] 1456
Failure Code [D1B0KB] 1458
Failure Code [D1B0KY] 1460
Failure Code [D1B0MC] 1462
Failure Code [D1E6KA] 1464
Failure Code [D1E6KB] 1466
Failure Code [D1E6KY] 1468
Failure Code [D5ZHKA] 1470
Failure Code [D5ZHKB] 1472
Failure Code [D5ZHL6] 1474
Failure Code [D811MC] 1476
Failure Code [D862KA] 1477
Failure Code [D8ALKA] 1478
Failure Code [D8ALKB] 1480
Failure Code [D8AQK4] 1482
Failure Code [D8AQKR] 1486
Failure Code [D8G1KT] 1490
Failure Code [D8G6KT] 1491
Failure Code [DAF0KT] 1492
Failure Code [DAF0MB] 1493
Failure Code [DAF0MC] 1494
Failure Code [DAF3KK] 1495
Failure Code [DAF8KB] 1497
Failure Code [DAFDKB] 1499
Failure Code [DAFGMC] 1501
Failure Code [DAFLKA] 1502
Failure Code [DAFLKB] 1504
Failure Code [DAFQKR] 1506
Failure Code [DAJ0KK] 1511
Failure Code [DAJ0KT] 1514
Failure Code [DAJ0MC] 1515
Failure Code [DAJ1KA] 1516
Failure Code [DAJ2KK] 1518
Failure Code [DAJ2KT] 1521
Failure Code [DAJ4KB] 1524
Failure Code [DAJ4KZ] 1526
Failure Code [DAJ5KX] (Applicable Machine: 95001 to 95033) 1528
Failure Code [DAJ5KX] (Applicable Machine: 95034 and Up) 1530
Failure Code [DAJ6KX] (Applicable Machine: 95001 to 95033) 1532
Failure Code [DAJ6KX] (Applicable Machine: 95034 and Up) 1534
Failure Code [DAJ9KQ] 1536
Failure Code [DAJLKA] 1537
Failure Code [DAJLKB] 1539
Failure Code [DAJQKR] 1541
Failure Code [DAJRKR] 1546
Failure Code [DAJRMA] 1551
Failure Code [DAZ9KQ] 1552
Failure Code [DAZQKR] 1553
Failure Code [DB2QKR] 1557
Failure Code [DB2RKR] 1563
Failure Code [DDAAL6] 1568
Failure Code [DDB6L4] 1570
Failure Code [DDD7KA] 1572
Failure Code [DDD7KY] 1574
Failure Code [DDE5MA] 1576
Failure Code [DDE7KA] 1578
Failure Code [DDE7KB] 1580
Failure Code [DDK3KA] 1582
Failure Code [DDK3KB] 1585
Failure Code [DDK6KA] 1588
Failure Code [DDK6KB] 1591
Failure Code [DDNRLD] (Applicable Machine: 95001 to 95033) 1594
Failure Code [DDNRLD] (Applicable Machine: 95034 and Up) 1596
Failure Code [DDS5L6] 1598
Failure Code [DF10KA] 1600
Failure Code [DF10KB] 1603
Failure Code [DGH1KX] 1606
Failure Code [DGR2KB] 1608
Failure Code [DGR2KZ] 1610
Failure Code [DHAAMA] 1612
Failure Code [DHACMA] 1614
Failure Code [DHH1KX] 1616
Failure Code [DHH1KY] 1618
Failure Code [DHTCL6] 1620
Failure Code [DJF1KA] 1622
Failure Code [DK55KA] 1623
Failure Code [DK55KY] 1626
Failure Code [DK55L5] 1629
Failure Code [DK5DKA] (Applicable Machine: 95001 to 95033) 1630
Failure Code [DK5DKA] (Applicable Machine: 95034 and Up) 1633
Failure Code [DK5DKY] (Applicable Machine: 95001 to 95033) 1636
Failure Code [DK5DKY] (Applicable Machine: 95034 and Up) 1639
Failure Code [DK5DL8] (Applicable Machine: 95001 to 95033) 1642
Failure Code [DK5DL8] (Applicable Machine: 95034 and Up) 1646
Failure Code [DK5EKA] (Applicable Machine: 95001 to 95033) 1650
Failure Code [DK5EKA] (Applicable Machine: 95034 and Up) 1653
Failure Code [DK5EKY] (Applicable Machine: 95001 to 95033) 1656
Failure Code [DK5EKY] (Applicable Machine: 95034 and Up) 1659
Failure Code [DLM3KA] 1662
Failure Code [DLM3LC] 1663
Failure Code [DLT3KX] 1665
Failure Code [DLT4KX] 1667
Failure Code [DLT4L0] 1669
Failure Code [DLT4LC] 1670
Failure Code [DPQ1KR] 1672
Failure Code [DPQ2KR] 1675
Failure Code [DPQ3KR] 1678
Failure Code [DSJ0KR] 1682
Failure Code [DT22KB] 1687
Failure Code [DV00KB] 1689
Failure Code [DW26KA] 1690
Failure Code [DW26KB] 1692
Failure Code [DW26KY] 1694
Failure Code [DW44KA] 1696
Failure Code [DW44KB] 1698
Failure Code [DW44KY] 1700
Failure Code [DWM1KA] (Applicable Machine: 95001 to 95033) 1701
Failure Code [DWM1KA] (Applicable Machine: 95034 and Up) 1702
Failure Code [DWM1KB] (Applicable Machine: 95001 to 95033) 1704
Failure Code [DWM1KB] (Applicable Machine: 95034 and Up) 1706
Failure Code [DWM1KY] (Applicable Machine: 95001 to 95033) 1708
Failure Code [DWM1KY] (Applicable Machine: 95034 and Up) 1709
Failure Code [DWN6KA] 1711
Failure Code [DWN6KB] 1713
Failure Code [DWN6KY] 1714
Failure Code [DWN7KA] 1715
Failure Code [DWN7KB] 1717
Failure Code [DWN7KY] 1718
Failure Code [DWN8KA] 1719
Failure Code [DWN8KB] 1721
Failure Code [DWN8KY] 1722
Failure Code [DWPBKA] 1723
Failure Code [DWPBKB] 1725
Failure Code [DWPBKY] 1727
Failure Code [DX19KA] 1729
Failure Code [DX19KB] 1732
Failure Code [DX19KY] 1734
Failure Code [DX20KA] 1736
Failure Code [DX20KB] 1738
Failure Code [DX20KY] 1740
Failure Code [DXH7KA] 1742
Failure Code [DXH7KB] 1744
Failure Code [DXH7KY] 1746
Failure Code [DXH8KA] 1748
Failure Code [DXH8KB] 1750
Failure Code [DXH8KY] 1752
Failure Code [DXHJKA] 1754
Failure Code [DXHJKB] 1756
Failure Code [DXHJKY] 1758
Failure Code [DXHKKA] 1760
Failure Code [DXHKKB] 1762
Failure Code [DXHKKY] 1764
Failure Code [F313KA] 1766
Failure Code [F313KB] 1768
Failure Code [F314KA] 1769
Failure Code [F314KB] 1771
Failure Code [F315KB] 1773
Failure Code [F315KY] 1775
Failure Code [F316KB] 1777
Failure Code [F316KY] 1779
Failure Code [F318KB] 1781
Failure Code [F318KY] 1783
Failure Code [F31AKB] 1784
Failure Code [F31AKY] 1786
Failure Code [F31BKB] 1788
Failure Code [F31BKY] 1790
Failure Code [F31CKB] 1792
Failure Code [F31CKY] 1794
Failure Code [F31DKB] 1796
Failure Code [F31DKY] 1798
Failure Code [F31EKB] 1800
Failure Code [F31EKY] 1802
Failure Code [FS10ZE] 1804
Failure Code [H2K0KA] 1805
Failure Code [H2K0KY] 1807
Failure Code [J141N1] 1809
Failure Code [LA00L3] 1810
Failure Code [M100N1] 1811
Failure Code [M400N1] 1812
Troubleshooting of Electrical System (E-Mode) 1813
Engine Does Not Start (Engine Does Not Crank) 1813
Manual Preheating System Does Not Operate 1819
Automatic Preheating System Does Not Operate 1822
While Preheating is in Operation, Preheating Monitor Does Not Come On 1825
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing 1827
LCD Unit on Machine Monitor Shows Nothing 1830
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) 1832
LCD Screen on Machine Monitor Does Not Show Correctly 1834
Meter Unit Display on Machine Monitor is Abnormal 1836
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal 1839
LED Unit Lamp on Machine Monitor is Abnormal 1842
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly 1844
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 1847
Switch Panel Buzzer of Machine Monitor is Abnormal 1850
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally 1853
DEF Level is Not Shown Correctly 1854
Rearview Monitor Does Not Come On or Backlight Flickers 1857
Rearview Monitor Images are Not Shown Clearly 1860
Rearview Monitor Brightness Cannot be Adjusted 1865
Night Mode Lamp of Rearview Monitor is Abnormal 1869
Radiator Coolant Level Caution Lamp Does Not Come On 1871
Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position 1872
Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low 1876
Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low 1877
Indication of HST Oil Temperature Gauge Does Not Increase, or HST Oil Temperature Caution Lamp Does Not Come On 1878
Fuel Gauge Does Not Show Normally 1879
Seatbelt Caution Lamp Does Not Show Normally 1881
Alarm Buzzer Does Not Operate 1882
Alarm Buzzer Does Not Stop 1883
Setting Does Not Change While You Operate the Traction Control Switch 1884
The Bucket Positioner Does Not Work or Cannot be Released 1886
The Boom Kick-out Does Not Work or Cannot be Released 1889
Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in Forward or Reverse Travel When Parking Brake is Released 1891
Directional Selector (FNR) Switch Mode is Not Selected or Not Released 1894
Traction Level Does Not Show MAX When Max Traction Switch is Turned on 1896
ECSS Function Cannot be Selected or Cannot be Released 1898
Horn Does Not Sound 1900
Horn Does Not Stop 1903
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On 1905
Clearance Lamp and Tail Lamp Do Not Come On or Go Out 1907
High and Low Beams of Headlamp Do Not Come On or Go Out 1911
Low Beam of Headlamp Does Not Come On or Go Out 1915
High Beam of Headlamp Does Not Come On or Go Out 1917
Front Working Lamp Does Not Come On or Go Out 1919
Rear Working Lamp Does Not Come On or Go Out 1924
Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out 1928
Turn Signal Lamp Does Not Come On or Go Out 1931
Hazard Lamp Does Not Come On or Go Out 1934
Brake Lamp Does Not Come On or Stays Lit 1938
Backup Lamp Does Not Come On or Stays Lit 1942
Backup Buzzer Does Not Sound or Continues to Sound 1946
Front Wiper Does Not Operate 1948
Rear Wiper Does Not Operate 1952
Window Washer Does Not Operate 1955
KOMTRAX System Does Not Operate Correctly 1958
Auto-Greasing Pump Display Shows [FCS] 1959
Auto-Greasing Pump Display Shows [FLL] 1960
Auto-Greasing System Does Not Operate or Stop 1961
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1962
Information Shown in Troubleshooting Table (H-Mode) 1962
Failure Mode and Cause Table 1963
Machine Can Not Move Forward or Reverse 1976
Machine Can Not Travel FORWARD (Machine Travels REVERSE Normally) 1978
Machine Can Not Travel REVERSE (Machine Travels FORWARD Normally) 1979
Travel Speed of FORWARD Travel and REVERSE Travel is Slow, or Power is Low 1980
Forward Travel Speed is Slow or Power is Low (Machine Travels REVERSE Normally) 1983
REVERSE Travel Speed is Slow or Power is Low (Machine Travels FORWARD Normally) 1985
Engine Speed Drops Largely or Engine Stops 1986
Machine Does Not Turn 1988
Steering Wheel is Heavy to Operate 1989
Machine Sways or Large Shocks are Made While Machine Turns 1990
Machine Unintentionally Turns to One Side When Machine Travels 1991
Wheel Brakes Do Not Operate or are Weak 1992
Wheel Brakes are Not Released or Drag 1994
Parking Brake Does Not Operate or is Weak 1995
Parking Brake is Not Released or Drags 1996
Boom Does Not Rise 1998
Boom Moves Slow or Lacks Lifting Force 2000
Rising Boom Slows Down at Specified Height 2002
Lift Cylinders Can Not Hold Bucket on Ground 2003
Hydraulic Drift of Boom is Large 2005
Boom Moves Up and Down During Operation 2006
Bucket Does Not Tilt Back 2007
Bucket Moves Slow or Lacks Tilt-Back Force 2009
Bucket Slows Down During Tilt Back Operation 2011
Bucket Cylinder Does Not Hold Bucket on Ground 2012
Hydraulic Drift of Bucket is Large 2014
Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold) 2015
Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move 2016
Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment 2017
Large Shocks are Made When Work Equipment Starts to Move and Stops 2018
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2020
ECSS Does Not Operate and Machine Pitches and Bounces 2021
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2022
Unusual Noise is Heard from Around Fan 2024
Troubleshooting of Engine (S-Mode) 2025
Information Shown in Troubleshooting Table (S-Mode) 2025
Engine Does Not Crank When Starting Switch is Turned to Start Position 2026
Engine Cranks but No Exhaust Smoke Comes Out 2027
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2028
Engine Startability is Unsatisfactory 2030
Engine Does Not Pick Up Smoothly 2032
Engine Stops During Operation 2034
Engine Does Not Rotate Smoothly 2036
Engine Lacks Output (or Lacks Power) 2037
Exhaust Color is Black (KDPF Becomes Clogged in Short Time) 2039
Engine Oil Consumption is Excessive 2041
Engine Oil Becomes Dirty Quickly 2042
Fuel Consumption is Excessive 2043
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2044
Engine Oil Pressure Drops 2045
Fuel Mixes Into Engine Oil 2047
Water Mixes Into Engine Oil (Milky) 2048
Coolant Temperature Increases Too High (Overheat) 2049
Unusual Noise is Heard 2050
Vibration is Excessive 2051
Air Cannot be Bled from Fuel Circuit 2052
Active Regeneration is Done Frequently 2053
Active Regeneration Continues Long 2054
White Smoke is Exhausted During Active Regeneration 2055
DEF Consumption is Excessive 2056
There is an Unusual Smell (Irritating Odor) 2057
Foreign Materials Enter DEF (DEF Increases) 2058
Troubleshooting for Auto-Greasing System 2059
Outline of Failure Display 2059
Troubleshooting for FCS 2060
Replacement of Pump Element 2061
Troubleshooting for Grease Supply System 2062
Replace Auto-Greasing Controller 2064
Assembly procedure when disassembled in troubleshooting 2065
50 Disassembly and Assembly 2067
Table of Contents 2068
Precautions Before Work 2073
Related Information on Disassembly and Assembly 2074
How to Read This Manual 2074
Coating Materials List 2075
Special Tool List 2080
Sketches of Special Tools 2099
Prepare 2110
Drain and Add Coolant 2110
How to Drain Coolant 2110
How to Add Coolant 2112
Drain and Add Hydraulic Oil 2114
How to Drain Hydraulic Oil 2115
How to Add Hydraulic Oil 2115
Drain and Add Fuel 2117
How to Drain Fuel 2117
How to Add Fuel 2118
Collect and Refill Refrigerant 2119
How to Collect Refrigerant 2119
How to Refill Refrigerant 2120
Engine and Cooling System 2122
Remove and Install Supply Pump Assembly 2122
How to Remove Supply Pump Assembly 2123
How to Install Supply Pump Assembly 2127
Remove and Install Injector Assembly 2132
How to Remove Injector Assembly 2133
How to Install Injector Assembly 2141
Remove and Install Cylinder Head Assembly 2150
How to Remove Cylinder Head Assembly 2152
How to Install Cylinder Head Assembly 2170
Remove and Install Starter Assembly 2194
How to Remove Starting Motor Assembly 2195
How to Install Starting Motor Assembly 2197
Remove and Install Air Conditioner Compressor Belt 2200
How to Remove Air Conditioner Compressor Belt 2200
How to Install Air Conditioner Compressor Belt 2202
Remove and Install Alternator Belt 2204
How to Remove Alternator Belt 2204
How to Install Alternator Belt 2208
Remove and Install Alternator Assembly 2213
How to Remove Alternator Assembly 2213
How to Install Alternator Assembly 2215
Remove and Install Automatic Tensioner 2218
How to Remove Auto-Tensioner 2218
How to Install Auto-Tensioner 2219
Remove and Install Radiator Assembly 2220
How to Remove Radiator Assembly 2221
How to Install Radiator Assembly 2228
Remove and Install Cooling Fan and Fan Motor Assembly 2237
How to Remove Cooling Fan Motor Assembly 2238
How to Install Cooling Fan Motor Assembly 2243
Remove and Install Hydraulic Oil Cooler Assembly 2248
How to Remove Hydraulic Oil Cooler Assembly 2248
How to Install Hydraulic Oil Cooler Assembly 2250
Remove and Install Aftercooler Assembly 2253
How to Remove Aftercooler Assembly 2253
How to Install Aftercooler Assembly 2255
Remove and Install Engine Assembly 2257
How to Remove Engine Assembly 2259
How to Install Engine Assembly 2284
Remove and Install Engine Front Oil Seal 2313
How to Remove Engine Front Oil Seal 2313
How to Install Engine Front Oil Seal 2315
Remove and Install Engine Rear Oil Seal 2317
How to Remove Engine Rear Oil Seal 2318
How to Install Engine Rear Oil Seal 2322
Remove and Install Engine Hood Assembly 2328
How to Remove Engine Hood Assembly 2329
How to Install Engine Hood Assembly 2338
Remove and Install Bellows Pipe Assembly 2347
How to Remove Bellows Pipe Assembly 2348
How to Install Bellows Pipe Assembly 2353
Remove and Install Fuel Tank Assembly 2359
How to Remove Fuel Tank Assembly 2360
How to Install Fuel Tank Assembly 2365
Remove and Install DEF Tank Assembly 2370
How to Remove DEF Tank Assembly 2372
How to Install DEF Tank Assembly 2378
Remove and Install DEF Tank Sensor Flange Assembly 2383
How to Remove DEF Tank Sensor Flange Assembly 2383
How to Install DEF Tank Sensor Flange Assembly 2385
Remove and Install DEF Tank Sensor 2389
How to Remove DEF Tank Sensor 2389
How to Install DEF Tank Sensor 2390
Remove and Install DEF Tank Strainer 2397
How to Remove DEF Tank Strainer 2397
How to Install DEF Tank Strainer 2397
Remove and Install KDPF Assembly 2399
How to Remove KDPF Assembly 2400
How to Install KDPF Assembly 2410
Disassemble and Assemble KDPF Assembly 2424
How to Disassemble KDPF Assembly 2424
How to Assemble KDPF Assembly 2428
Remove and Install SCR Assembly 2434
How to Remove SCR Assembly 2435
How to Install SCR Assembly 2443
Remove and Install KDPF and SCR Assembly 2455
How to Remove KDPF and SCR Assembly 2456
How to Install KDPF and SCR Assembly 2466
Remove and Install Exhaust Throttle Valve 2477
How to Remove Exhaust Throttle Valve 2478
How to Install Exhaust Throttle Valve 2483
Remove and Install DEF Injector 2489
How to Remove DEF Injector 2490
How to Install DEF Injector 2494
Remove and Install DEF Pump 2501
How to Remove DEF Pump 2502
How to Install DEF Pump 2508
Remove and Install DEF Hose 2513
How to Remove DEF Hose 2514
How to Install DEF Hose 2529
Remove and Install Air Cleaner Assembly 2544
How to Remove Air Cleaner Assembly 2545
How to Install Air Cleaner Assembly 2548
Remove and Install Air Conditioner Compressor Assembly 2552
How to Remove Air Conditioner Compressor Assembly 2552
How to Install Air Conditioner Compressor Assembly 2554
Remove and Install Air Conditioner Condenser Assembly 2556
How to Remove Air Conditioner Condenser Assembly 2556
How to Install Air Conditioner Condenser Assembly 2559
Remove and Install Oil Catch Tank 2562
How to Remove Oil Catch Tank 2563
How to Install Oil Catch Tank 2564
Remove and Install Exhaust Pipe Cover 2566
How to Remove Exhaust Pipe Cover 2566
How to Install Exhaust Pipe Cover 2568
Power Train 2571
Remove and Install HST Pump Assembly, Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump Assembly 2571
How to Remove HST Pump Assembly, Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump Assembly 2573
How to Install HST Pump Assembly, Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump Assembly 2581
Remove and Install HST Motor 1 Assembly 2591
How to Remove HST Motor 1 Assembly 2592
How to Install HST Motor 1 Assembly 2594
Remove and Install HST Motor 2 Assembly 2597
How to Remove HST Motor 2 Assembly 2598
How to Install HST Motor 2 Assembly 2602
Remove and Install Transfer Assembly 2606
How to Remove Transfer Assembly 2607
How to Install Transfer Assembly 2615
Disassemble and Assemble Transfer Assembly 2623
How to Disassemble Transfer Assembly 2624
How to Assemble Transfer Assembly 2639
Remove and Install Parking Brake Assembly 2658
How to Remove Parking Brake Assembly 2659
How to Install Parking Brake Assembly 2660
Remove and Install Parking Brake Cylinder Assembly 2662
How to Remove Parking Brake Cylinder Assembly 2663
How to Install Parking Brake Cylinder Assembly 2664
Disassemble and Assemble Parking Brake Assembly 2666
How to Disassemble Parking Brake Assembly 2666
How to Assemble Parking Brake Assembly 2669
Remove and Install Front Axle Assembly 2673
How to Remove Front Axle Assembly 2674
How to Install Front Axle Assembly 2677
Remove and Install Rear Axle Assembly 2680
How to Remove Rear Axle Assembly 2681
How to Install Rear Axle Assembly 2685
Disassemble and Assemble Axle Housing Assembly 2691
How to Disassemble Axle Housing Assembly 2691
How to Assemble Axle Housing Assembly 2696
Disassemble and Assemble Differential Assembly 2704
How to Disassemble Differential Assembly 2705
How to Assemble Differential Assembly 2718
Undercarriage and Frame 2740
Remove and Install Center Hinge Pin 2740
How to Remove Center Hinge Pin 2742
How to Install Center Hinge Pin 2751
Remove and Install Counterweight Assembly 2762
How to Remove Counterweight Assembly 2763
How to Install Counterweight Assembly 2774
Hydraulic System 2786
Remove and Install Hydraulic Tank Assembly 2786
How to Remove Hydraulic Tank Assembly 2787
How to Install Hydraulic Tank Assembly 2793
Remove and Install Control Valve Assembly 2799
How to Remove Control Valve Assembly 2801
How to Install Control Valve Assembly 2807
Disassemble and Assemble Hydraulic Cylinder Assembly 2814
How to Disassemble Hydraulic Cylinder Assembly 2815
How to Assemble Hydraulic Cylinder Assembly 2818
Work Equipment 2825
Remove and Install Work Equipment Assembly 2825
How to Remove Work Equipment Assembly 2826
How to Install Work Equipment Assembly 2830
CAB Related Parts 2839
Remove and Install Operator Cab Assembly 2839
How to Remove Operator Cab Assembly 2841
How to Install Operator Cab Assembly 2852
Remove and Install Operator Cab Glass (Adhered Glass) 2863
How to Remove Operator Cab Glass (Adhered Glass) 2863
How to Install Operator Cab Glass (Adhered Glass) 2864
Remove and Install Air Conditioner Unit Assembly 2873
How to Remove Air Conditioner Unit Assembly 2873
How to Install Air Conditioner Unit Assembly 2879
Remove and Install Operator Seat Assembly 2886
How to Remove Operator Seat Assembly 2886
How to Install Operator Seat Assembly 2886
How to Remove and Install Seat Belt 2888
How to Remove Seat Belt 2888
How to Install Seatbelt 2888
Electrical System 2890
Remove and Install Engine Controller Assembly 2890
How to Remove Engine Controller Assembly 2891
How to Install Engine Controller Assembly 2895
Remove and Install HST Controller Assembly 2900
How to Remove HST Controller Assembly 2900
How to Install HST Controller Assembly 2902
Remove and Install Air Conditioner Controller Assembly 2904
How to Remove Air Conditioner Controller Assembly 2904
How to Install Air Conditioner Controller Assembly 2905
Remove and Install Monitor Controller Assembly 2907
How to Remove Monitor Controller Assembly 2907
How to Install Monitor Controller Assembly 2910
Remove and Install Machine Monitor Assembly 2912
How to Remove Machine Monitor Assembly 2912
How to Install Machine Monitor Assembly 2915
Remove and Install Intake Manifold Pressure and Temperature Sensor 2918
How to Remove Intake Manifold Pressure and Temperature Sensor 2918
How to Install Intake Manifold Pressure and Temperature Sensor 2919
Remove and Install KDPF Temperature Sensor 2921
How to Remove KDPF Temperature Sensor 2922
How to Install KDPF Temperature Sensor 2929
Remove and Install KDPF Differential Pressure Sensor 2936
How to Remove KDPF Differential Pressure Sensor 2937
How to Install KDPF Differential Pressure Sensor 2940
Remove and Install SCR Temperature Sensor 2943
How to Remove SCR Temperature Sensor 2944
How to Install SCR Temperature Sensor 2950
Remove and Install SCR Outlet NOx Sensor 2958
How to Remove SCR Outlet NOx Sensor 2959
How to Install SCR Outlet NOx Sensor 2964
Remove and Install Gateway Function Controller 2970
How to Remove Gateway Function Controller 2970
How to Install Gateway Function Controller 2972
Remove and Install Communication Terminal 2974
How to Remove Communication Terminal 2974
How to Install Communication Terminal 2976
60 Maintenance Standard 2981
Table of Contents 2982
Engine and Cooling System 2983
Maintenance Standard for Engine Mount 2983
Maintenance Standard for Damper 2984
Maintenance Standard for Cooling Fan Motor 2985
Power Train 2989
Maintenance Standard for Drive Shaft 2989
Maintenance Standard for Transfer 2990
Maintenance Standard for Transfer Mount 2999
Maintenance Standard for Front Axle 3000
Maintenance Standard for Rear Axle 3001
Maintenance Standard for Front Torque Proportioning Differential 3002
Maintenance Standard for Rear Torque Proportioning Differential 3004
Maintenance Standard for Limited Slip Differential 3006
Maintenance Standard for Front Final Drive 3008
Maintenance Standard for Rear Final Drive 3010
Steering System 3012
Maintenance Standard for Steering Column 3012
Maintenance Standard for Priority Valve 3013
Maintenance Standard for Steering Cylinder 3014
Maintenance Standard for Secondary Steering Valve 3016
Brake System 3017
Maintenance Standard for Brake Circuit Accumulator Charge Valve 3017
Maintenance Standard for Slack Adjuster 3018
Maintenance Standard for Front Brake 3019
Maintenance Standard for Rear Brake 3020
Maintenance Standard for Parking Brake 3021
Undercarriage and Frame 3022
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin 3022
Hydraulic System 3027
Maintenance Standard for Hydraulic Tank 3027
Maintenance Standard for Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump 3028
Maintenance Standard for Control Valve 3030
Maintenance Standard for Multifunction Mono-Lever PPC Valve 3033
Maintenance Standard for Attachment EPC Solenoid Valve 3035
Work Equipment 3036
Maintenance Standard for Work Equipment Linkage 3036
Maintenance Standard for Bucket 3039
Maintenance Standard for Lift Cylinder 3040
Maintenance Standard for Bucket Cylinder 3041
Maintenance Standard for Coupler Plunger 3042
CAB Related Parts 3043
Maintenance Standard for CAB Mount 3043
80 Others 3045
Table of Contents 3046
Precautions Before Work 3048
Air Conditioner System 3049
Precautions for Refrigerant 3049
Air Conditioner Component 3050
Specifications of Air Conditioner 3052
Structure and Function of Refrigeration Cycle 3053
Outline of Refrigeration Cycle 3054
Component Parts of Air Conditioner System 3056
Air Conditioner Unit 3056
Configuration Diagram of Air Conditioner Unit 3056
Function of Air Conditioner Unit 3057
Component Parts of Air Conditioner Unit 3058
Function of Evaporator as Air Conditioner Unit Component 3058
Function of Inside Air Temperature Sensor as Air Conditioner Unit Component 3058
Function of Blower Amplifier as Air Conditioner Unit Component 3059
Function of Blower OFF Relay as Air Conditioner Unit Component 3059
Function of Compressor Clutch Relay as Air Conditioner Unit Component 3059
Function of Heater Core as Air Conditioner Unit Component 3059
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3059
Function of Servo Motor as Air Conditioner Unit Component 3059
Function of Expansion Valve as Air Conditioner Unit Component 3060
Function of Dual Pressure Switch 3060
Air Conditioner Controller 3061
Structure of Air Conditioner Controller 3061
Compressor 3062
Structure of Compressor 3062
Specifications of Compressor 3062
Function of Compressor 3062
Condenser 3063
Structure of Condenser 3063
Specifications of Condenser 3063
Function of Condenser 3063
Receiver Drier 3064
Structure of Receiver Dryer 3064
Specifications of Receiver Dryer 3064
Function of Receiver Dryer 3064
Air Conditioner Related Sensors 3065
Function of Sunlight Sensor 3065
Function of Outside Air Temperature Sensor 3065
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3066
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3068
System Diagram of Air Conditioner 3071
Input and Output Signals of Air Conditioner Controller 3072
Function of Air Conditioner Controller 3073
Locations of Air Conditioner Parts and Layout of Connectors 3074
Examine Air Conditioner with Self-Diagnosis Function 3080
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3081
Examine Temperature Control Function 3082
How to Examine Temperature Control Function 3082
Examine Vent (Mode) Changeover 3084
How to Examine Vent (Mode) Changeover 3084
Examine Fresh/Recirc Air Changeover 3086
How to Examine Fresh/Recirc Air Changeover 3086
Examine Evaporator Temperature Sensor 3088
Examine Relay 3090
How to Examine Relay 3090
Air Conditioner Troubleshooting Chart 1 3092
Air Conditioner Troubleshooting Chart 2 3093
Failure Code [879AKA] 3096
Failure Code [879AKB] 3098
Failure Code [879BKA] 3100
Failure Code [879BKB] 3102
Failure Code [879CKA] 3104
Failure Code [879CKB] 3106
Failure Code [879DKZ] 3108
Failure Code [879EMC] 3110
Failure Code [879FMC] 3111
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3112
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3115
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3118
Troubleshooting for Fresh/Recirc Air Changeover 3122
Troubleshooting by Gauge Pressure 3124
Connect Service Tool 3127
How to Connect Service Tool 3128
Precautions for Disconnection and Connection of Air Conditioner Piping 3129
Handle Compressor Oil 3131
90 Circuit Diagrams 3133
Table of Contents 3134
How to Read the Codes for Electric Cable 3135
Hydraulic Circuit Diagram 3139
Symbols Used in Hydraulic Circuit Diagram 3139
Hydraulic Circuit Diagram (1/2) 3143
Hydraulic Circuit Diagram (2/2) 3145
Electrical Circuit Diagram 3147
Symbols Used in Electric Circuit Diagram 3147
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (1/13) 3151
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (2/13) 3153
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (3/13) 3155
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (4/13) 3157
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (5/13) 3159
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (6/13) 3161
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (7/13) 3163
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (8/13) 3165
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (9/13) 3167
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (10/13) 3169
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (11/13) 3171
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (12/13) 3173
Electrical Circuit Diagram of Machine (Applicable Machine: 95001 to 95033) (13/13) 3175
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (1/13) 3177
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (2/13) 3179
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (3/13) 3181
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (4/13) 3183
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (5/13) 3185
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (6/13) 3187
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (7/13) 3189
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (8/13) 3191
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (9/13) 3193
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (10/13) 3195
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (11/13) 3197
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (12/13) 3199
Electrical Circuit Diagram of Machine (Applicable Machine: 95034 and Up) (13/13) 3201
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (1/10) 3203
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (2/10) 3205
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (3/10) 3207
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (4/10) 3209
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (5/10) 3211
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (6/10) 3213
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (7/10) 3215
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (8/10) 3217
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (9/10) 3219
Electrical Circuit Diagram of Floor (Applicable Machine: 95001 to 95033) (10/10) 3221
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (1/10) 3223
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (2/10) 3225
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (3/10) 3227
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (4/10) 3229
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (5/10) 3231
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (6/10) 3233
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (7/10) 3235
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (8/10) 3237
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (9/10) 3239
Electrical Circuit Diagram of Floor (Applicable Machine: 95034 and Up) (10/10) 3241
Index 3243

DESCRIPTION:

Komatsu WA200-8E0 Wheel Loader Shop Manual SEN06859-07 – PDF DOWNLOAD 

SERIAL NUMBERS 95001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• 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.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see STRUCTURE AND OPERATION, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the 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 Specification
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.

S.V 28/12/24