Komatsu Wheel Loader WA200-7 Shop Manual SEN06503-08 PDF

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Komatsu Wheel Loader WA200-7 Shop Manual SEN06503-08 – PDF DOWNLOAD

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Komatsu Wheel Loader WA200-7 Shop Manual SEN06503-08 – PDF DOWNLOAD

Language : English
Pages :4668
Downloadable : Yes
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DESCRIPTION:

Komatsu Wheel Loader WA200-7 Shop Manual SEN06503-08 – PDF DOWNLOAD

SERIAL NUMBERS 80001 and up

Foreword, safety and general information
Important safety notice

•  Appropriate servicing and repair are extremely important to ensure safe operation of the machine.
  Theshop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
  Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
•  The symbol mark k is used for such matters that require special cautions during the work. The work indicated
  by the caution mark should be performed according to the instructions with special attention to the
  cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe first
  and take every necessary measure.

General precautions 

Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work. q Before performing any greasing or repairs, read all the safety labels stuck to the machine.

• For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual. q Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• q When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• q When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING”
• in the operator’s compartment. q Only qualified workers must perform the work and operation which require license or qualification. q Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc. q If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition. q Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe

TABLE OF CONTENTS:

Komatsu Wheel Loader WA200-7 Shop Manual SEN06503-08 – PDF DOWNLOAD

SERIAL NUMBERS 80001 and up

Cover 1
00 Index and foreword 3
Index and foreword 4
Index 4
Important safety notice 16
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling equipment of fuel system devices 27
Handling of intake system parts 28
Handling of hydraulic equipment 29
Method of disconnecting and connecting of push-pull type coupler 31
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation 45
Practical use of KOMTRAX 50
Standard tightening torque table 51
List of Abbreviation 57
Conversion table 61
01 Specifications 67
Specifications 70
Specification dimension drawing 70
Specifications 72
Weight table 80
Table of fuel, coolant, and lubricants 84
10 Structure and function 87
Engine and cooling system 90
VFT 90
EGR system piping drawing 94
EGR system circuit diagram 96
EGR valve 98
EGR cooler 100
KCCV layout drawing 102
KCCV ventilator 105
KDOC muffler 109
Damper 111
Cooling system 112
Cooling system hydraulic piping diagram 113
Cooling fan motor 114
Power train 123
Power train 123
Power train system diagram 124
Drive shaft 126
HST hydraulic piping diagram 127
HST pump 128
HST motor 136
Transfer 142
Clutch solenoid valve 148
Axle 149
Differential 151
Torque proportioning differential 154
Limited slip differential 155
Final drive 158
Steering system 161
Steering piping diagram 161
Orbitrol valve 162
Steering column 170
Priority valve 171
Emergency steering valve 174
Brake system 177
Brake piping diagram 177
Brake valve 178
Charge valve 182
Accumulator (for brake) 186
Slack adjuster 187
Brake 189
Parking brake control 192
Parking brake 193
Parking brake cylinder 194
Parking brake solenoid valve 195
Inching valve 197
Undercarriage and frame 198
Axle mount and center hinge pin 198
Hydraulic system 200
Hydraulic component layout 200
Work equipment control lever linkage 202
Hydraulic tank 203
Accumulator (for PPC circuit) 205
Work equipment control valve 206
PPC valve 219
Attachment EPC valve 225
Work equipment lock solenoid valve 226
ECSS valve 227
Accumulator (for ECSS) 229
2-way restrictor valve 230
Cushion valve 231
Accumulator (for oil cooler circuit) 232
Quadruple gear pump 233
Quick coupler solenoid valve 234
Work equipment 235
Work equipment linkage 235
Bucket 237
Bucket positioner and boom kick-out 238
Cab and its attachments 244
Cab 244
Electrical system 245
Machine monitor system 245
Machine monitor 250
Electrical system (HST controller system) 272
System component parts 288
HST controller 294
ECSS 298
KOMTRAX system 300
Engine starting circuit 303
Engine stopping circuit 305
Preheating system 306
Automatic preheating system 307
Manual preheating system 307
Engine output limit function 308
Automatic warm-up function 308
Parking brake control system 309
Multi-function mono-lever 313
Sensor 315
20 Standard value table 331
Standard value table 333
Standard value table for engine 333
Standard value table for machine 335
30 Testing and adjusting 343
Related information on testing and adjusting 346
Tools for testing and adjusting 346
Engine and cooling system 349
Testing and adjusting engine speed 349
Testing exhaust gas temperature 351
Testing exhaust gas color 352
Testing and adjusting valve clearance 354
Testing compression pressure 356
Testing blowby pressure 359
Testing engine oil pressure 360
Testing boost pressure 361
Handling equipment of fuel system devices 363
Releasing remaining pressure from fuel system 363
Testing fuel pressure 364
Testing fuel discharge, return and leakage 369
Bleeding air from fuel system 374
Testing fuel circuit for leakage 376
Handling cylinder cutout mode operation 377
Handling no-injection cranking operation 377
Testing KDPF and muffler stack for looseness and damage 378
Testing KDOC function 378
Testing installed condition of cylinder heads and manifolds 379
Testing engine piping for damage and looseness 379
Testing and adjusting air conditioner compressor belt tension 380
Testing and replacing alternator belt 381
Testing and replacing auto-tensioner 383
Power train 385
Testing oil leakage from axle final drive 385
Testing drive shaft for looseness, backlash, and damage 386
Testing accelerator pedal 387
Testing and adjusting HST oil pressure 389
Testing transfer clutch control pressure 394
Steering system 395
Testing directional lever 395
Testing and adjusting steering wheel 396
Testing work equipment control lever 398
Testing and adjusting steering circuit oil pressure 399
Bleeding air from steering circuit 401
Brake system 402
Testing brake pedal 402
Testing and adjusting brake pedal and linkage 403
Testing braking performance 404
Testing and adjusting accumulator charge pressure 405
Testing wheel brake oil pressure 407
Testing lowering of wheel brake pressure 408
Testing wear of wheel brake disc 411
Bleeding air from wheel brake circuit 412
Releasing remaining pressure in brake accumulator circuit 413
Testing parking brake performance 414
Testing parking brake release pressure 415
Method of releasing parking brake manually 416
Hydraulic system 417
Testing and adjusting cooling fan speed 417
Testing cooling fan pump circuit oil pressure 418
Testing work equipment PPC oil pressure 419
Testing and adjusting work equipment oil pressure 420
Bleeding air from each part 421
Releasing remaining pressure in hydraulic circuit 422
Work equipment 423
Testing and adjusting bucket positioner 423
Testing and adjusting boom kick-out switch 424
Checking the proximity switch working pilot lamp 425
Electrical system 427
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 427
Special functions of machine monitor 429
KOMTRAX terminal start-up procedure 483
Lamp indication of KOMTRAX terminal 486
Handling voltage circuit of controller 490
Test diodes 491
Pm Clinic 492
Pm Clinic service 492
40 Troubleshooting 495
Related information on troubleshooting 503
Points to remember when performing troubleshooting 503
How to proceed in troubleshooting 505
Checks before troubleshooting 507
Check procedure before troubleshooting 509
Preparation for troubleshooting of electrical system 527
Classification and procedures of troubleshooting 532
Symptom and troubleshooting No 536
Information described in troubleshooting table 538
Procedure for troubleshooting of open circuit in wiring harness of pressure sensor system 540
Connector list and layout 542
Connection table of connector by No of pins 555
T-box and T-adapter list 592
Fuse location table 596
Failure code list 599
Troubleshooting by failure code (Display of code) 607
Failure code [2F00MB] Malfunction of Parking Brake 607
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 609
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 611
Failure code [6091NX] HST Filter Clogging 613
Failure code [7RHYKA] Open Circuit of Fan Motor EPC Solenoid Output 615
Failure code [7RHYKB] Ground Fault of Fan Motor EPC Solenoid Output 617
Failure code [7RHYKY] Hot Short of Fan Motor EPC Solenoid Output 619
Failure code [989FN1] Travel Speed Overrun Alarm 621
Failure code [AB00L6] Discharge of Alternator R Terminal 622
Failure code [AB00MA] Ground Fault or Open Circuit of Battery Relay Status Signal Line, or Insufficient Battery Charging 624
Failure code [B@BAZG] Engine Oil Pressure Low 626
Failure code [B@BCNS] Engine Water Overheat 627
Failure code [B@BCZK] Engine Coolant Level Low 628
Failure code [B@C6NS] Front Brake Oil Temperature Overheat (This Alarm) 630
Failure code [B@CRNS] HST Oil Temperature Overheat 631
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 632
Failure code [CA122] Charge Air Pressure Sensor High Error 633
Failure code [CA123] Charge Air Pressure Sensor Low Error 635
Failure code [CA131] Throttle Sensor High Error 637
Failure code [CA132] Throttle Sensor Low Error 639
Failure code [CA144] Coolant Temperature Sensor High Error 641
Failure code [CA145] Coolant Temperature Sensor Low Error 643
Failure code [CA153] Charge Air Temperature Sensor High Error 645
Failure code [CA154] Chg Air Temp Sensor Low Error 647
Failure code [CA187] Sensor 2 Supply Voltage Low Error 649
Failure code [CA221] Ambient Pressure Sensor High Error 651
Failure code [CA222] Ambient Pressure Sensor Low Error 653
Failure code [CA227] Sensor 2 Supply Voltage High Error 655
Failure code [CA234] Engine Overspeed 656
Failure code [CA238] Ne Speed Sensor Supply Volt Error 657
Failure code [CA239] Ne Speed Sens Supply Volt High Error 658
Failure code [CA271] IMV/PCV1 Short Error 659
Failure code [CA272] IMV/PCV1 Open Error 661
Failure code [CA295] Ambient Press Sens In Range Error 663
Failure code [CA322] Injector #1 (L#1) Open/Short Error 664
Failure code [CA324] Injector #3 (L#3) Open/Short Error 666
Failure code [CA331] Injector #2 (L#2) Open/Short Error 668
Failure code [CA332] Injector #4 (L#4) Open/Short Error 670
Failure code [CA343] Engine Controller Internal Failure 672
Failure code [CA351] Injectors Drive Circuit Error 673
Failure code [CA352] Sensor 1 Supply Voltage Low Error 674
Failure code [CA356] Mass Air Flow Sensor High Error 676
Failure code [CA357] Mass Air Flow Sensor Low Error 678
Failure code [CA386] Sensor 1 Supply Voltage High Error 680
Failure code [CA428] Water in Fuel Sensor High Error 681
Failure code [CA429] Water in Fuel Sensor Low Error 683
Failure code [CA431] Idle Validation Sw Error 685
Failure code [CA432] Idle Validation Process Error 688
Failure code [CA435] Engine Oil Pressure Sw Error 690
Failure code [CA441] Battery Voltage Low Error 691
Failure code [CA442] Battery Voltage High Error 693
Failure code [CA449] Rail Press Very High Error 694
Failure code [CA451] Common Rail Pressure Sensor High Error 695
Failure code [CA452] Common Rail Pressure Sensor Low Error 697
Failure code [CA466] KVGT Motor Driver Position Error 699
Failure code [CA488] Chg Air Temp High Torque Derate 701
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error 702
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error 704
Failure code [CA553] Common Rail Pressure High Error 1 706
Failure code [CA555] Crankcase Press High Error 1 707
Failure code [CA556] Crankcase Press High Error 2 708
Failure code [CA559] Rail Press Low Error 1 709
Failure code [CA689] Engine Ne Speed Sensor Error 712
Failure code [CA691] Intake Air Temp Sens High Error 714
Failure code [CA692] Intake Air Temp Sens Low Error 716
Failure code [CA697] ECM Internal Temperature Sensor High Error 718
Failure code [CA698] EMC Internal Temperature Sensor Low Error 719
Failure code [CA731] Engine Bkup Speed Sensor Phase Error 720
Failure code [CA778] Engine Bkup Speed Sensor Error 722
Failure code [CA1117] Persistent Data Lost Error 727
Failure code [CA1695] Sensor 5 Supply Voltage High Error 728
Failure code [CA1696] Sensor 5 Supply Voltage Low Error 729
Failure code [CA1843] Crankcase Press Sens High Error 730
Failure code [CA1844] Crankcase Press Sens Low Error 732
Failure code [CA1896] EGR Valve Stuck Error 734
Failure code [CA1942] Crankcase Press Sens In-Range Error 735
Failure code [CA1961] EGR Motor Driver IC Over Temp Error 736
Failure code [CA2185] Throttle Sensor Supply Voltage High Error 737
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error 739
Failure code [CA2249] Rail Press Low Error 2 741
Failure code [CA2272] EGR Valve Position Sensor Low Error 742
Failure code [CA2311] IMV Solenoid Error 744
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error 745
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error 747
Failure code [CA2357] EGR Valve Servo Error 749
Failure code [CA2373] Exhaust Manifold Pressure Sensor High Error 750
Failure code [CA2374] Exhaust Manifold Pressure Sensor Low Error 752
Failure code [CA2375] EGR Orifice Temperature Sensor High Error 754
Failure code [CA2376] EGR Orifice Temperature Sensor Low Error 756
Failure code [CA2554] Exhaust Manifold Pressure Sensor In-Range Error 758
Failure code [CA2555] Grid Heater Relay Voltage Low Error 759
Failure code [CA2556] Grid Heater Relay Voltage High Error 761
Failure code [CA2961] EGR Orifice Temperature High Error 1 763
Failure code [CA2973] Charge Air Pressure Sensor In-Range Error 764
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 765
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 767
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error 769
Failure code [CA3741] Common Rail Pressure Valve Trip Error 771
Failure code [CA3918] KVGT Stuck Error 772
Failure code [CA3919] KVGT Motor Driver IC Over Temperature Error 773
Failure code [CA3921] KVGT Servo Error 2 774
Failure code [CA3922] KVGT Motor Driver Open Error 775
Failure code [CA3923] KVGT Motor Driver Short Error 777
Failure code [D110L4] Disconnection or Short to Ground of Battery Relay Signal Line 779
Failure code [D160KA] Disconnection of Backup Lamp Relay Output 781
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output 783
Failure code [D160KY] Hot Short of Backup Lamp Relay Output 785
Failure code [D191KA] Disconnection of Neutral Output Relay 787
Failure code [D191KB] Ground Fault of Neutral Output Relay 789
Failure code [D191KY] Hot Short of Neutral Output Relay 791
Failure code [D192KA] Disconnection of ECSS Solenoid Relay 793
Failure code [D192KB] Ground Fault of ECSS Solenoid Relay 795
Failure code [D192KY] Hot Short of ECSS Solenoid Relay 797
Failure code [D1B0KA] Disconnection of HST Safety Relay 799
Failure code [D1B0KB] Ground Fault of HST Safety Relay 801
Failure code [D1B0KY] Hot Short of HST Safety Relay 803
Failure code [D1B0MC] Malfunction of HST Safety Relay 805
Failure code [D1E6KA] Disconnection of Parking Brake Relay 806
Failure code [D1E6KB] Ground Fault of Parking Brake Relay 808
Failure code [D1E6KY] Hot Short of Parking Brake Relay 810
Failure code [D5ZHKA] Failure of Key SW C Signal 812
Failure code [D5ZHKB] Key SW C Signal Hot Short Circuit 814
Failure code [D5ZHL6] Disconnection of Key SW C 816
Failure code [DAF3KK] Controller Power Source Low (MON) 818
Failure code [DAF5KP] 5 V Sensor Power Supply: Ground Fault 820
Failure code [DAF6KP] 24 V Sensor Power Supply: Ground Fault 822
Failure code [DAFRKR] Machine Monitor CAN2 Communication Error (Machine Monitor) 824
Failure code [DAJ0KK] Controller Power Source Low (HST) 825
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) 828
Failure code [DAJ0MC] HST Controller Malfunction 829
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) 830
Failure code [DAJ2KK] Solenoid Power Source Low (HST) 832
Failure code [DAJ4KB] Ground Fault of Solenoid Self-Holding Relay (HST) 835
Failure code [DAJ4KZ] Failure of Solenoid Self-Holding Relay (HST) 837
Failure code [DAJ5KX] Failure of 5 V Power Source 0 (HST) 839
Failure code [DAJ6KX] Failure of 5 V Power Source 1 (HST) 841
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) 843
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) 844
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) 846
Failure code [DAJQKR] CAN2 Disconnection (HST) 848
Failure code [DAJRMA] Inconsistency of Option Selection (HST) 849
Failure code [DB2QKR] CAN2 Disconnection (Engine Controller) 850
Failure code [DB2RKR] CAN1 Disconnection (Engine Controller) 854
Failure code [DBE6KX] 24V Output Power Supply System Failure 857
Failure code [DD1NL4] Fan Auto Reverse Switch Signal Error 859
Failure code [DD1NLD] Fan Reverse Switch Signal: Abnormal 861
Failure code [DDB6L4] Parking Brake Signal Malfunction 863
Failure code [DDD7KA] Failure of Variable Speed Control 865
Failure code [DDD7KY] Hot Short of Variable Speed Control 867
Failure code [DDE5MA] Disconnection of Steering Oil Pressure Switch (Emergency Steering Control Switch) 869
Failure code [DDK3KA] FNR SW Input Signal Disconnection 871
Failure code [DDK3KB] FNR SW Input Signal Short Circuit 873
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 875
Failure code [DDK6KY] FNR Lever Input Signal Disconnection (Hot Short) 877
Failure code [DDNRLD] Ground Fault of Work Equipment Lock Switch 879
Failure code [DDS5L6] Low Steering Oil Pressure (Emergency Steering Control) 881
Failure code [DF10KA] Disconnection of Speed Range Input Switch 883
Failure code [DF10KB] Disconnection of Speed Range Selector Switch (Hot Short) 888
Failure code [DGH1KX] HST Oil Temperature Sensor Short to Ground 893
Failure code [DGR2KB] Ground Fault of Brake Oil Temperature Sensor 895
Failure code [DGR2KZ] Failure of Brake Oil Temperature Sensor 897
Failure code [DHH1KX] Failure of HST Oil Pressure Sensor 899
Failure code [DHH1KY] Hot Short of HST Oil Pressure Sensor 901
Failure code [DHPCKX] Failure of Boom Pressure Sensor (Bottom) 903
Failure code [DHPDKX] Failure of Boom Pressure Sensor (Head) 905
Failure code [DHTCL6] HST Oil Filter Clogging Detection Failure 907
Failure code [DJF1KA] Disconnection or Hot Short Circuit of Fuel Level Sensor 909
Failure code [DK5DKA] Failure of 3rd Lever Potentiometer Sensor (Main) 911
Failure code [DK5DKY] Hot Short of 3rd Lever Potentiometer Sensor (Main) 914
Failure code [DK5DL8] 3rd Lever Potentiometer Sensor (Main & Sub) Disagree 916
Failure code [DK5EKA] Failure of 3rd Lever Potentiometer Sensor (Sub) 919
Failure code [DK5EKY] Hot Short of 3rd Lever Potentiometer Sensor (Sub) 922
Failure code [DKA0KX] Failure of Boom Angle Sensor 924
Failure code [DLM3KA] Failure of Cooling Fan Speed Sensor 926
Failure code [DLM3LC] Ground Fault of Cooling Fan Speed Sensor 928
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) 929
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) 931
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) 933
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) 936
Failure code [DT22KB] Ground Fault of Work Equip Lock Indicator 938
Failure code [DV00KY] Hot Short of Alarm Buzzer 940
Failure code [DW26KA] Open Circuit of Motor 2 Solenoid 942
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid 944
Failure code [DW26KY] Hot Short of Motor 2 Solenoid 946
Failure code [DW44KA] Open Circuit of Directional Pressure Selection Solenoid 948
Failure code [DW44KB] Ground Fault of Directional Pressure Selection Solenoid 950
Failure code [DW44KY] Hot Short of Directional Pressure Selection Solenoid 952
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid 954
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid 956
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid 958
Failure code [DX19KA] Disconnection of Motor 1 Solenoid 960
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid 963
Failure code [DX19KY] Hot Short of Motor 1 Solenoid 965
Failure code [DX20KA] Disconnection of Clutch EPC Solenoid 967
Failure code [DX20KB] Ground Fault of Clutch EPC Solenoid 970
Failure code [DX20KY] Hot Short of Clutch EPC Solenoid 972
Failure code [DXH7KA] Disconnection of Reverse Solenoid 974
Failure code [DXH7KB] Ground Fault of Reverse Solenoid 976
Failure code [DXH7KY] Hot Short of Reverse Solenoid 978
Failure code [DXH8KA] Disconnection of Forward Solenoid 979
Failure code [DXH8KB] Ground Fault of Forward Solenoid 981
Failure code [DXH8KY] Hot Short of Forward Solenoid 983
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) 984
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 986
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) 988
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) 989
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 991
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) 993
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal 994
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal 997
Failure code [J141N1] Steering Pump Over Run 999
Failure code [LA00L3] Failure of Fan Reverse1000
Failure code [M100N1] HST Pump Over Run1001
Failure code [M400N1] HST Motor 1 Over Run1002
Troubleshooting of electrical system (E-mode)1003
E-1 Engine does not start1003
E-2 Manual preheating system does not work1008
E-3 Automatic preheating system does not work1011
E-4 While preheating is working, preheating monitor does not light up1013
E-5 When starting switch is turned to ON position, nothing is displayed on machine monitor1015
E-6 Travel speed is slow1018
E-7 ECSS does not operate1020
E-8 ECSS remains being operated1023
E-9 Boom kick-out does not work or is not reset1026
E-10 Bucket positioner does not work or is not reset1029
E-11 Boom FLOAT holding does not work or is not reset1032
E-12 Directional selection does not work normally1035
E-13 Fan does not rotate in reverse1046
E-14 Fan remains in reverse rotation mode1049
E-15 Wipers do not operate1051
E-16 Window washer does not operate1056
E-17 Headlamp, clearance lamp, tail lamp or license-plate lamp does not light up or does not go out1059
E-18 Working lamp does not light up or does not go out1068
E-19 Turn signal and hazard lamp do not light up or do not go out1073
E-20 Stop lamp does not light up or remains lighting up1080
E-21 Backup lamp does not light up or remains lighting up1083
E-22 Backup alarm does not sound or does not stop sounding1086
E-23 Horn does not sound or does not stop sounding1088
E-24 Alarm buzzer does not sound or does not stop sounding1091
E-25 KOMTRAX system does not operate normally1093
E-26 Fuel gauge does not indicate correct level1095
E-27 Seat belt caution lamp indication is incorrect1097
Troubleshooting for hydraulic and mechanical system (H-mode)1099
Information described in troubleshooting table (H-mode)1099
System chart of hydraulic and mechanical systems1100
Failure mode and cause table1102
H-1 Machine travels neither forward nor in reverse1108
H-2 Machine does not travel forward (normally travels in reverse)1110
H-3 Machine does not travel in reverse (normally travels forward)1111
H-4 Both forward and reverse travel speeds are low1112
H-5 Forward travel speed is low (normal when traveling in reverse)1114
H-6 Reverse travel speed is low (normal when traveling forward)1115
H-7 Machine lacks power when traveling both forward and in reverse1116
H-8 Machine lacks power when traveling forward (normal when traveling in reverse)1118
H-9 Machine lacks power when traveling in reverse (normal when traveling forward)1119
H-10 Engine stalls during travel or engine speed drops significantly1120
H-11 Machine does not turn1121
H-12 Steering wheel is heavy to turn1123
H-13 Machine sways or large shocks are made while machine turns1124
H-14 Machine turns to either side unintentionally during traveling1125
H-15 Brake does not work or it is weak1126
H-16 Brake is not released or drags1127
H-17 Parking brake does not work or it is weak1128
H-18 Parking brake is not released or drags1129
H-19 Boom does not rise1130
H-20 Boom moves slow or lacks lifting force1131
H-21 Boom rising speed lowers at certain height1132
H-22 Lift cylinder cannot hold down bucket (bucket rises off ground)1133
H-23 Hydraulic drift of boom is large1134
H-24 Boom wobbles during operation1138
H-25 Bucket does not tilt back1139
H-26 Bucket moves slow or lacks tilting back force1140
H-27 Bucket speed lowers in tilt-back motion1141
H-28 Bucket cylinder cannot hold down bucket (bucket rises off ground)1142
H-29 Hydraulic drift of bucket is large1143
H-30 Loaded bucket wobbles during travel (with work equipment valve at “HOLD”)1144
H-31 Boom and bucket control levers do not move smoothly and are heavy to move1145
H-32 Engine speed lowers remarkably or engine stalls while work equipment is operated1146
H-33 Large shock is made when work equipment starts and stops1147
H-34 When certain work equipment is relieved hydraulically, other work equipment moves1148
H-35 ECSS does not operate and machine pitches and bounds1149
H-36 Fan speed is abnormal (too high or low, or fan does not rotate)1150
H-37 Unusual noise is heard from around fan1152
Troubleshooting of engine (S-mode)1153
Information mentioned in troubleshooting table (S mode)1153
S-1 Engine does not crank when starting switch is turned to START position1154
S-2 Engine cranks but no exhaust smoke comes out1155
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)1156
S-4 Engine startability is poor1157
S-5 Engine does not pick up smoothly1159
S-6 Engine stops during operation1161
S-7 Engine runs rough or is unstable1162
S-8 Engine lacks power1163
S-9 Exhaust smoke is black1165
S-10 Engine oil consumption is excessive1167
S-11 Oil becomes contaminated quickly1168
S-12 Fuel consumption is excessive1169
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)1170
S-14 Oil pressure drops1171
S-15 Fuel mixes into engine oil1172
S-16 Water mixes into engine oil (milky)1173
S-17 Coolant temperature rises too high (overheating)1174
S-18 Unusual noise is heard1175
S-19 Vibration is excessive1176
S-20 Air cannot be bled from fuel circuit1177
50 Disassembly and assembly1179
General information on disassembly and assembly1182
How to read this manual1182
Coating materials list1184
Special tool list1188
Sketches of special tools1192
Engine and cooling system1202
Removal and installation of fuel supply pump assembly1202
Removal and installation of fuel injector assembly1206
Removal and installation of engine hood assembly1214
Removal and installation of cylinder head assembly1217
Removal and installation of radiator assembly1228
Removal and installation of air aftercooler assembly1231
Removal and installation of hydraulic oil cooler assembly1233
Removal and installation of engine assembly1235
Removal and installation of belt for alternator and air conditioner compressor1240
Removal and installation of engine front oil seal assembly1242
Removal and installation of engine rear oil seal assembly1246
Removal and installation of cooling fan and fan motor assembly1250
Removal and installation of fuel tank assembly1253
Removal and installation of KCCV ventilator assembly1255
Removal and installation of KDOC muffler1256
Removal and installation of EGR cooler assembly1257
Removal and installation of EGR valve assembly1259
Power train1261
Removal and installation of transfer assembly1261
Disassembly and assembly of transfer assembly1265
Removal and installation of parking brake assembly1288
Removal and installation of parking brake cylinder assembly1290
Disassembly and assembly of parking brake assembly1291
Removal and installation of front axle assembly1297
Removal and installation of rear axle assembly1299
Disassembly and assembly of axle housing assembly1302
Disassembly and assembly of differential assembly1311
Undercarriage and frame1336
Removal and installation of center hinge pin1336
Removal and installation of counterweight assembly1345
Hydraulic system1348
Removal and installation of HST pump and quadruple type gear pump assembly1348
Removal and installation of HST motor 1 assembly1352
Removal and installation of HST motor 2 assembly1354
Removal and installation of work equipment control valve assembly1357
Removal and installation of ECSS (Electronically Controlled Suspension System) valve assembly1359
Removal and installation of hydraulic tank assembly1361
Disassembly and assembly of hydraulic cylinder assembly1363
Work equipment1367
Removal and installation of work equipment assembly1367
Cab and its attachments1373
Removal and installation of operator’s cab and floor frame assembly1373
Removal and installation of operator’s cab glass (adhered glass)1378
Disassembly and assembly of operator’s seat1386
Removal and installation of air conditioner unit assembly1396
Removal and installation of air conditioner compressor assembly1402
Electrical system1404
Removal and installation of machine monitor1404
Removal and installation of engine controller assembly1406
Removal and installation of HST controller assembly1408
Removal and installation of KOMTRAX terminal assembly1409
60 Maintenance standard1411
Engine and cooling system1413
Engine mount and transfer mount1413
Damper1414
Cooling system1415
Cooling fan motor1416
Power train1418
Drive shaft1418
Transfer1419
Axle1427
Differential1429
Limited slip differential1433
Final drive1435
Steering system1438
Orbitrol valve1438
Steering cylinder1439
Steering column1441
Priority valve1442
Emergency steering valve1443
Brake system1444
Charge valve1444
Slack adjuster1446
Brake1447
Parking brake1449
Undercarriage and frame1450
Axle mount and center hinge pin1450
Hydraulic system1454
Hydraulic tank1454
Work equipment control valve1455
PPC valve1461
ECSS valve1464
Quadruple gear pump1465
Work equipment1467
Work equipment linkage1467
Bucket1469
Bucket positioner and boom kick-out1470
Work equipment cylinder1471
80 Appendix1473
Air conditioner1475
Precautions for refrigerant1475
Air conditioner component1476
Configuration and function of refrigeration cycle1478
Outline of refrigeration cycle1479
Air conditioner unit1481
Functions of main components in air conditioner unit1482
Blower and intake unit1483
Compressor1484
Condenser1485
Receiver drier1486
Air conditioner control panel1487
Procedure for troubleshooting1488
Circuit diagram and arrangement of connector pins1490
System diagram1492
Details of air conditioner unit1494
Parts and connectors layout1495
Inspection by self-diagnosis function (displays diagnosis on the control panel)1497
Testing temperature control system1498
Testing FRESH/RECIRC air changeover1499
Testing evaporator temperature sensor1501
Testing relays1502
Troubleshooting chart 11503
Troubleshooting chart 21505
Information described in troubleshooting table1508
Troubleshooting for power supply system (Air conditioner does not operate)1509
Troubleshooting for compressor and refrigerant system (Air is not cooled)1513
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)1516
Troubleshooting for temperature control1519
Troubleshooting for FRESH/RECIRC air changeover1522
Connection of service tool1524
Troubleshooting by gauge pressure1526
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit1529
Handling of compressor oil1531
90 Diagrams and drawings1535
Hydraulic diagrams and drawings1537
Symbols used in hydraulic circuit diagrams1537
Hydraulic circuit diagram1539
Electrical diagrams and drawings1540
Symbols used in electric circuit diagrams1540
Electrical circuit diagram1544
Index1555

S.M 29/12/24