Komatsu WA200-7 Wheel Loader Shop Manual (80001 and up) – SEN06503-03

This Complete Service Repair Workshop Manual PDF Download for the Komatsu WA200-7 (SN: 80001 and up) Wheel Loader has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Komatsu WA200-7 Wheel Loader
Serial Numbers : 80001 and up

TABLE OF CONTENTS :

00 Index and foreword
01 Specifications
10 Structure and function
20 Standard value table
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and assembly
60 Maintenance standard
80 Appendix
90 Diagrams and drawings
Index

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEN06503-03
Total Pages : 1556

This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
00 Index and foreword
– Index and foreword
– – Index
– Foreword, safety and general information
– – Important safety notice
– – – Precautions to prevent fire
– – – Action if fire occurs
– – – Dispose of waste materials
– – How to read the shop manual
– – Explanation of terms for maintenance standard
– – Handling equipment of fuel system devices
– – Handling of intake system parts
– – Handling of hydraulic equipment
– – Method of disconnecting and connecting of push-pull type coupler
– – Handling of electrical equipment
– – How to read electric wire code
– – Precautions when performing operation
– – Practical use of KOMTRAX
– – Standard tightening torque table
– – List of Abbreviation
– – Conversion table

01 Specifications
– Specifications
– – Specification dimension drawing
– – Specifications
– – Weight table
– – Table of fuel, coolant, and lubricants

10 Structure and function
– Engine and cooling system
– – VFT
– – EGR system piping drawing
– – EGR system circuit diagram
– – EGR valve
– – EGR cooler
– – KCCV layout drawing
– – KCCV ventilator
– – – CDR valve
– – – Forming of condensed water and emulsion
– – KDOC muffler
– – Damper
– – Cooling system
– – Cooling system hydraulic piping diagram
– – Cooling fan motor
– Power train
– – Power train
– – Power train system diagram
– – Drive shaft
– – HST hydraulic piping diagram
– – HST pump
– – HST motor
– – Transfer
– – Clutch solenoid valve
– – Axle
– – Differential
– – Torque proportioning differential
– – Limited slip differential
– – Final drive
– Steering system
– – Steering piping diagram
– – Orbitrol valve
– – Steering column
– – Priority valve
– – Emergency steering valve
– Brake system
– – Brake piping diagram
– – Brake valve
– – Charge valve
– – Accumulator (for brake)
– – Slack adjuster
– – Brake
– – Parking brake control
– – Parking brake
– – Parking brake cylinder
– – Parking brake solenoid valve
– – Inching valve
– Undercarriage and frame
– – Axle mount and center hinge pin
– Hydraulic system
– – Hydraulic component layout
– – Work equipment control lever linkage
– – Hydraulic tank
– – Accumulator (for PPC circuit)
– – Work equipment control valve
– – PPC valve
– – Attachment EPC valve
– – Work equipment lock solenoid valve
– – ECSS valve
– – Accumulator (for ECSS)
– – 2-way restrictor valve
– – Cushion valve
– – Accumulator (for oil cooler circuit)
– – Quadruple gear pump
– – Quick coupler solenoid valve
– Work equipment
– – Work equipment linkage
– – Bucket
– – Bucket positioner and boom kick-out
– Cab and its attachments
– – Cab
– Electrical system
– – Machine monitor system
– – Machine monitor
– – Electrical system (HST controller system)
– – System component parts
– – HST controller
– – ECSS
– – KOMTRAX system
– – Engine starting circuit
– – Engine stopping circuit
– – Preheating system
– – Automatic preheating system
– – Manual preheating system
– – Engine output limit function
– – Automatic warm-up function
– – Parking brake control system
– – Multi-function mono-lever
– – Sensor

20 Standard value table
– Standard value table
– – Standard value table for engine
– – Standard value table for machine

30 Testing and adjusting
– Related information on testing and adjusting
– – Tools for testing and adjusting
– Engine and cooling system
– – Testing and adjusting engine speed
– – Testing exhaust gas temperature
– – Testing exhaust gas color
– – Testing and adjusting valve clearance
– – Testing compression pressure
– – Testing blowby pressure
– – Testing engine oil pressure
– – Testing boost pressure
– – Handling equipment of fuel system devices
– – Releasing remaining pressure from fuel system
– – Testing fuel pressure
– – Testing fuel discharge, return and leakage
– – Bleeding air from fuel system
– – Testing fuel circuit for leakage
– – Handling cylinder cutout mode operation
– – Handling no-injection cranking operation
– – Testing KDPF and muffler stack for looseness and damage
– – Testing KDOC function
– – Testing installed condition of cylinder heads and manifolds
– – Testing engine piping for damage and looseness
– – Testing and adjusting air conditioner compressor belt tension
– – Replacing alternator belt
– Power train
– – Testing oil leakage from axle final drive
– – Testing drive shaft for looseness, backlash, and damage
– – Testing accelerator pedal
– – Testing and adjusting HST oil pressure
– – Testing transfer clutch control pressure
– Steering system
– – Testing directional lever
– – Testing and adjusting steering wheel
– – Testing work equipment control lever
– – Testing and adjusting steering circuit oil pressure
– – Bleeding air from steering circuit
– Brake system
– – Testing brake pedal
– – Testing and adjusting brake pedal and linkage
– – Testing braking performance
– – Testing and adjusting accumulator charge pressure
– – Testing wheel brake oil pressure
– – Testing lowering of wheel brake pressure
– – Testing wear of wheel brake disc
– – Bleeding air from wheel brake circuit
– – Releasing remaining pressure in brake accumulator circuit
– – Testing parking brake performance
– – Testing parking brake release pressure
– – Method of releasing parking brake manually
– Hydraulic system
– – Testing and adjusting cooling fan speed
– – Testing cooling fan pump circuit oil pressure
– – Testing work equipment PPC oil pressure
– – Testing and adjusting work equipment oil pressure
– – Bleeding air from each part
– – Releasing remaining pressure in hydraulic circuit
– Work equipment
– – Testing and adjusting bucket positioner
– – Testing and adjusting boom kick-out switch
– – Checking the proximity switch working pilot lamp
– Electrical system
– – Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
– – Special functions of machine monitor
– – KOMTRAX terminal start-up procedure
– – Lamp indication of KOMTRAX terminal
– – Handling voltage circuit of controller
– – Test diodes
– Pm Clinic
– – Pm Clinic service

40 Troubleshooting
– Related information on troubleshooting
– – Points to remember when performing troubleshooting
– – How to proceed in troubleshooting
– – Checks before troubleshooting
– – Check procedure before troubleshooting
– – – Walk-around check
– – – Check according to the check procedure
– – Preparation for troubleshooting of electrical system
– – Classification and procedures of troubleshooting
– – Symptom and troubleshooting No.
– – Information described in troubleshooting table
– – Procedure for troubleshooting of open circuit in wiring harness of pressure sensor system
– – Connector list and layout
– – Connection table of connector by No. of pins
– – T-box and T-adapter list
– – Fuse location table
– – Failure code list
– Troubleshooting by failure code (Display of code)
– – Failure code [2F00MB] Malfunction of Parking Brake
– – Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
– – Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
– – Failure code [6091NX] HST Filter Clogging
– – Failure code [7RHYKA] Open Circuit of Fan Motor EPC Solenoid Output
– – Failure code [7RHYKB] Ground Fault of Fan Motor EPC Solenoid Output
– – Failure code [7RHYKY] Hot Short of Fan Motor EPC Solenoid Output
– – Failure code [989FN1] Travel Speed Overrun Alarm
– – Failure code [AB00L6] Discharge of Alternator R Terminal
– – Failure code [AB00MA] Ground Fault or Open Circuit of Battery Relay Status Signal Line, or Insufficient Battery Charging
– – Failure code [B@BAZG] Engine Oil Pressure Low
– – Failure code [B@BCNS] Engine Water Overheat
– – Failure code [B@BCZK] Engine Coolant Level Low
– – Failure code [B@C6NS] Front Brake Oil Temperature Overheat (This Alarm)
– – Failure code [B@CRNS] HST Oil Temperature Overheat
– – Failure code [CA115] Eng Ne and Bkup Speed Sens Error
– – Failure code [CA122] Charge Air Pressure Sensor High Error
– – Failure code [CA123] Charge Air Pressure Sensor Low Error
– – Failure code [CA131] Throttle Sensor High Error
– – Failure code [CA132] Throttle Sensor Low Error
– – Failure code [CA144] Coolant Temperature Sensor High Error
– – Failure code [CA145] Coolant Temperature Sensor Low Error
– – Failure code [CA153] Charge Air Temperature Sensor High Error
– – Failure code [CA154] Chg Air Temp Sensor Low Error
– – Failure code [CA187] Sensor 2 Supply Voltage Low Error
– – Failure code [CA221] Ambient Pressure Sensor High Error
– – Failure code [CA222] Ambient Pressure Sensor Low Error
– – Failure code [CA227] Sensor 2 Supply Voltage High Error
– – Failure code [CA234] Engine Overspeed
– – Failure code [CA238] Ne Speed Sensor Supply Volt Error
– – Failure code [CA239] Ne Speed Sens Supply Volt High Error
– – Failure code [CA271] IMV/PCV1 Short Error
– – Failure code [CA272] IMV/PCV1 Open Error
– – Failure code [CA322] Injector #1 (L#1) Open/Short Error
– – Failure code [CA324] Injector #3 (L#3) Open/Short Error
– – Failure code [CA331] Injector #2 (L#2) Open/Short Error
– – Failure code [CA332] Injector #4 (L#4) Open/Short Error
– – Failure code [CA343] Engine Controller Internal Failure
– – Failure code [CA351] Injectors Drive Circuit Error
– – Failure code [CA352] Sensor 1 Supply Voltage Low Error
– – Failure code [CA356] Mass Air Flow Sensor High Error
– – Failure code [CA357] Mass Air Flow Sensor Low Error
– – Failure code [CA386] Sensor 1 Supply Voltage High Error
– – Failure code [CA428] Water in Fuel Sensor High Error
– – Failure code [CA429] Water in Fuel Sensor Low Error
– – Failure code [CA431] Idle Validation Sw Error
– – Failure code [CA432] Idle Validation Process Error
– – Failure code [CA435] Engine Oil Pressure Sw Error
– – Failure code [CA441] Battery Voltage Low Error
– – Failure code [CA442] Battery Voltage High Error
– – Failure code [CA449] Rail Press Very High Error
– – Failure code [CA451] Common Rail Pressure Sensor High Error
– – Failure code [CA452] Common Rail Pressure Sensor Low Error
– – Failure code [CA466] KVGT Motor Driver Position Error
– – Failure code [CA488] Chg Air Temp High Torque Derate
– – Failure code [CA515] Rail Pressure Sensor Sup Volt High Error
– – Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error
– – Failure code [CA553] Common Rail Pressure High Error 1
– – Failure code [CA555] Crankcase Press High Error 1
– – Failure code [CA556] Crankcase Press High Error 2
– – Failure code [CA559] Rail Press Low Error 1
– – Failure code [CA689] Engine Ne Speed Sensor Error
– – Failure code [CA691] Intake Air Temp Sens High Error
– – Failure code [CA692] Intake Air Temp Sens Low Error
– – Failure code [CA697] ECM Internal Temperature Sensor High Error
– – Failure code [CA698] EMC Internal Temperature Sensor Low Error
– – Failure code [CA731] Engine Bkup Speed Sensor Phase Error
– – Failure code [CA778] Engine Bkup Speed Sensor Error
– – Failure code [CA1117] Persistent Data Lost Error
– – Failure code [CA1695] Sensor 5 Supply Voltage High Error
– – Failure code [CA1696] Sensor 5 Supply Voltage Low Error
– – Failure code [CA1843] Crankcase Press Sens High Error
– – Failure code [CA1844] Crankcase Press Sens Low Error
– – Failure code [CA1896] EGR Valve Stuck Error
– – Failure code [CA1942] Crankcase Press Sens In-Range Error
– – Failure code [CA1961] EGR Motor Driver IC Over Temp Error
– – Failure code [CA2185] Throttle Sensor Supply Voltage High Error
– – Failure code [CA2186] Throttle Sensor Supply Voltage Low Error
– – Failure code [CA2249] Rail Press Low Error 2
– – Failure code [CA2272] EGR Valve Position Sensor Low Error
– – Failure code [CA2311] IMV Solenoid Error
– – Failure code [CA2349] EGR Valve Solenoid Open Circuit Error
– – Failure code [CA2353] EGR Valve Solenoid Short Circuit Error
– – Failure code [CA2357] EGR Valve Servo Error
– – Failure code [CA2373] Exhaust Manifold Pressure Sensor High Error
– – Failure code [CA2374] Exhaust Manifold Pressure Sensor Low Error
– – Failure code [CA2375] EGR Orifice Temperature Sensor High Error
– – Failure code [CA2376] EGR Orifice Temperature Sensor Low Error
– – Failure code [CA2554] Exhaust Manifold Pressure Sensor In-Range Error
– – Failure code [CA2555] Grid Heater Relay Voltage Low Error
– – Failure code [CA2556] Grid Heater Relay Voltage High Error
– – Failure code [CA2961] EGR Orifice Temperature High Error 1
– – Failure code [CA2973] Charge Air Pressure Sensor In-Range Error
– – Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
– – Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
– – Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error
– – Failure code [CA3741] Common Rail Pressure Valve Trip Error
– – Failure code [CA3918] KVGT Stuck Error
– – Failure code [CA3919] KVGT Motor Driver IC Over Temperature Error
– – Failure code [CA3921] KVGT Servo Error 2
– – Failure code [CA3922] KVGT Motor Driver Open Error
– – Failure code [CA3923] KVGT Motor Driver Short Error
– – Failure code [D110L4] Disconnection or Short to Ground of Battery Relay Signal Line
– – Failure code [D160KA] Disconnection of Backup Lamp Relay Output
– – Failure code [D160KB] Ground Fault of Backup Lamp Relay Output
– – Failure code [D160KY] Hot Short of Backup Lamp Relay Output
– – Failure code [D191KA] Disconnection of Neutral Output Relay
– – Failure code [D191KB] Ground Fault of Neutral Output Relay
– – Failure code [D191KY] Hot Short of Neutral Output Relay
– – Failure code [D192KA] Disconnection of ECSS Solenoid Relay
– – Failure code [D192KB] Ground Fault of ECSS Solenoid Relay
– – Failure code [D192KY] Hot Short of ECSS Solenoid Relay
– – Failure code [D1B0KA] Disconnection of HST Safety Relay
– – Failure code [D1B0KB] Ground Fault of HST Safety Relay
– – Failure code [D1B0KY] Hot Short of HST Safety Relay
– – Failure code [D1B0MC] Malfunction of HST Safety Relay
– – Failure code [D1E6KA] Disconnection of Parking Brake Relay
– – Failure code [D1E6KB] Ground Fault of Parking Brake Relay
– – Failure code [D1E6KY] Hot Short of Parking Brake Relay
– – Failure code [D5ZHKA] Failure of Key SW C Signal
– – Failure code [D5ZHKB] Key SW C Signal Hot Short Circuit
– – Failure code [D5ZHL6] Disconnection of Key SW C
– – Failure code [DAF3KK] Controller Power Source Low (MON)
– – Failure code [DAF5KP] 5 V Sensor Power Supply: Ground Fault
– – Failure code [DAF6KP] 24 V Sensor Power Supply: Ground Fault
– – Failure code [DAFRKR] Machine Monitor CAN2 Communication Error (Machine Monitor)
– – Failure code [DAJ0KK] Controller Power Source Low (HST)
– – Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST)
– – Failure code [DAJ0MC] HST Controller Malfunction
– – Failure code [DAJ1KA] Disconnection of Key SW ACC (HST)
– – Failure code [DAJ2KK] Solenoid Power Source Low (HST)
– – Failure code [DAJ4KB] Ground Fault of Solenoid Self-Holding Relay (HST)
– – Failure code [DAJ4KZ] Failure of Solenoid Self-Holding Relay (HST)
– – Failure code [DAJ5KX] Failure of 5 V Power Source 0 (HST)
– – Failure code [DAJ6KX] Failure of 5 V Power Source 1 (HST)
– – Failure code [DAJ9KQ] Inconsistency of Model Selection (HST)
– – Failure code [DAJLKA] Operating Lamp Open Circuit (HST)
– – Failure code [DAJLKB] Operating Lamp Short Circuit (HST)
– – Failure code [DAJQKR] CAN2 Disconnection (HST)
– – Failure code [DAJRMA] Inconsistency of Option Selection (HST)
– – Failure code [DB2QKR] CAN2 Disconnection (Engine Controller)
– – Failure code [DB2RKR] CAN1 Disconnection (Engine Controller)
– – Failure code [DBE6KX] 24V Output Power Supply System Failure
– – Failure code [DD1NL4] Fan Auto Reverse Switch Signal Error
– – Failure code [DD1NLD] Fan Reverse Switch Signal: Abnormal
– – Failure code [DDB6L4] Parking Brake Signal Malfunction
– – Failure code [DDD7KA] Failure of Variable Speed Control
– – Failure code [DDD7KY] Hot Short of Variable Speed Control
– – Failure code [DDE5MA] Disconnection of Steering Oil Pressure Switch (Emergency Steering Control Switch)
– – Failure code [DDK3KA] FNR SW Input Signal Disconnection
– – Failure code [DDK3KB] FNR SW Input Signal Short Circuit
– – Failure code [DDK6KA] FNR Lever Input Signal Disconnection
– – Failure code [DDK6KY] FNR Lever Input Signal Disconnection (Hot Short)
– – Failure code [DDNRLD] Ground Fault of Work Equipment Lock Switch
– – Failure code [DDS5L6] Low Steering Oil Pressure (Emergency Steering Control)
– – Failure code [DF10KA] Disconnection of Speed Range Input Switch
– – Failure code [DF10KB] Disconnection of Speed Range Selector Switch (Hot Short)
– – Failure code [DGH1KX] HST Oil Temperature Sensor Short to Ground
– – Failure code [DGR2KB] Ground Fault of Brake Oil Temperature Sensor
– – Failure code [DGR2KZ] Failure of Brake Oil Temperature Sensor
– – Failure code [DHH1KX] Failure of HST Oil Pressure Sensor
– – Failure code [DHH1KY] Hot Short of HST Oil Pressure Sensor
– – Failure code [DHPCKX] Failure of Boom Pressure Sensor (Bottom)
– – Failure code [DHPDKX] Failure of Boom Pressure Sensor (Head)
– – Failure code [DHTCL6] HST Oil Filter Clogging Detection Failure
– – Failure code [DJF1KA] Disconnection or Hot Short Circuit of Fuel Level Sensor
– – Failure code [DK5DKA] Failure of 3rd Lever Potentiometer Sensor (Main)
– – Failure code [DK5DKY] Hot Short of 3rd Lever Potentiometer Sensor (Main)
– – Failure code [DK5DL8] 3rd Lever Potentiometer Sensor (Main & Sub) Disagree
– – Failure code [DK5EKA] Failure of 3rd Lever Potentiometer Sensor (Sub)
– – Failure code [DK5EKY] Hot Short of 3rd Lever Potentiometer Sensor (Sub)
– – Failure code [DKA0KX] Failure of Boom Angle Sensor
– – Failure code [DLM3KA] Failure of Cooling Fan Speed Sensor
– – Failure code [DLM3LC] Ground Fault of Cooling Fan Speed Sensor
– – Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B)
– – Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A)
– – Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B)
– – Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B)
– – Failure code [DT22KB] Ground Fault of Work Equip. Lock Indicator
– – Failure code [DV00KY] Hot Short of Alarm Buzzer
– – Failure code [DW26KA] Open Circuit of Motor 2 Solenoid
– – Failure code [DW26KB] Ground Fault of Motor 2 Solenoid
– – Failure code [DW26KY] Hot Short of Motor 2 Solenoid
– – Failure code [DW44KA] Open Circuit of Directional Pressure Selection Solenoid
– – Failure code [DW44KB] Ground Fault of Directional Pressure Selection Solenoid
– – Failure code [DW44KY] Hot Short of Directional Pressure Selection Solenoid
– – Failure code [DX19KA] Disconnection of Motor 1 Solenoid
– – Failure code [DX19KB] Ground Fault of Motor 1 Solenoid
– – Failure code [DX19KY] Hot Short of Motor 1 Solenoid
– – Failure code [DX20KA] Disconnection of Clutch EPC Solenoid
– – Failure code [DX20KB] Ground Fault of Clutch EPC Solenoid
– – Failure code [DX20KY] Hot Short of Clutch EPC Solenoid
– – Failure code [DXH7KA] Disconnection of Reverse Solenoid
– – Failure code [DXH7KB] Ground Fault of Reverse Solenoid
– – Failure code [DXH7KY] Hot Short of Reverse Solenoid
– – Failure code [DXH8KA] Disconnection of Forward Solenoid
– – Failure code [DXH8KB] Ground Fault of Forward Solenoid
– – Failure code [DXH8KY] Hot Short of Forward Solenoid
– – Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)
– – Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)
– – Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)
– – Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)
– – Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)
– – Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)
– – Failure code [H2K0KA] Failure of Quick Coupler Lock Signal
– – Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal
– – Failure code [J141N1] Steering Pump Over Run
– – Failure code [LA00L3] Failure of Fan Reverse
– – Failure code [M100N1] HST Pump Over Run
– – Failure code [M400N1] HST Motor 1 Over Run
– Troubleshooting of electrical system (E-mode)
– – E-1 Engine does not start
– – E-2 Manual preheating system does not work
– – E-3 Automatic preheating system does not work
– – E-4 While preheating is working, preheating monitor does not light up
– – E-5 When starting switch is turned to ON position, nothing is displayed on machine monitor
– – E-6 Travel speed is slow
– – E-7 ECSS does not operate
– – E-8 ECSS remains being operated
– – E-9 Boom kick-out does not work or is not reset
– – E-10 Bucket positioner does not work or is not reset
– – E-11 Boom FLOAT holding does not work or is not reset
– – E-12 Directional selection does not work normally
– – E-13 Fan does not rotate in reverse
– – E-14 Fan remains in reverse rotation mode
– – E-15 Wipers do not operate
– – E-16 Window washer does not operate
– – E-17 Headlamp, clearance lamp, tail lamp or license-plate lamp does not light up or does not go out
– – E-18 Working lamp does not light up or does not go out
– – E-19 Turn signal and hazard lamp do not light up or do not go out
– – E-20 Stop lamp does not light up or remains lighting up
– – E-21 Backup lamp does not light up or remains lighting up
– – E-22 Backup alarm does not sound or does not stop sounding
– – E-23 Horn does not sound or does not stop sounding
– – E-24 Alarm buzzer does not sound or does not stop sounding
– – E-25 KOMTRAX system does not operate normally
– – E-26 Fuel gauge does not indicate correct level
– – E-27 Seat belt caution lamp indication is incorrect
– Troubleshooting for hydraulic and mechanical system (H-mode)
– – Information described in troubleshooting table (H-mode)
– – System chart of hydraulic and mechanical systems
– – Failure mode and cause table
– – H-1 Machine travels neither forward nor in reverse
– – H-2 Machine does not travel forward (normally travels in reverse)
– – H-3 Machine does not travel in reverse (normally travels forward)
– – H-4 Both forward and reverse travel speeds are low
– – H-5 Forward travel speed is low (normal when traveling in reverse)
– – H-6 Reverse travel speed is low (normal when traveling forward)
– – H-7 Machine lacks power when traveling both forward and in reverse
– – H-8 Machine lacks power when traveling forward (normal when traveling in reverse)
– – H-9 Machine lacks power when traveling in reverse (normal when traveling forward)
– – H-10 Engine stalls during travel or engine speed drops significantly
– – H-11 Machine does not turn
– – H-12 Steering wheel is heavy to turn
– – H-13 Machine sways or large shocks are made while machine turns
– – H-14 Machine turns to either side unintentionally during traveling
– – H-15 Brake does not work or it is weak
– – H-16 Brake is not released or drags
– – H-17 Parking brake does not work or it is weak
– – H-18 Parking brake is not released or drags
– – H-19 Boom does not rise
– – H-20 Boom moves slow or lacks lifting force
– – H-21 Boom rising speed lowers at certain height
– – H-22 Lift cylinder cannot hold down bucket (bucket rises off ground)
– – H-23 Hydraulic drift of boom is large
– – H-24 Boom wobbles during operation
– – H-25 Bucket does not tilt back
– – H-26 Bucket moves slow or lacks tilting back force
– – H-27 Bucket speed lowers in tilt-back motion
– – H-28 Bucket cylinder cannot hold down bucket (bucket rises off ground)
– – H-29 Hydraulic drift of bucket is large
– – H-30 Loaded bucket wobbles during travel (with work equipment valve at “HOLD”)
– – H-31 Boom and bucket control levers do not move smoothly and are heavy to move
– – H-32 Engine speed lowers remarkably or engine stalls while work equipment is operated
– – H-33 Large shock is made when work equipment starts and stops
– – H-34 When certain work equipment is relieved hydraulically, other work equipment moves
– – H-35 ECSS does not operate and machine pitches and bounds
– – H-36 Fan speed is abnormal (too high or low, or fan does not rotate)
– – H-37 Unusual noise is heard from around fan
– Troubleshooting of engine (S-mode)
– – Information mentioned in troubleshooting table (S mode)
– – S-1 Engine does not crank when starting switch is turned to START position
– – S-2 Engine cranks but no exhaust smoke comes out
– – S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)
– – S-4 Engine startability is poor
– – S-5 Engine does not pick up smoothly
– – S-6 Engine stops during operation
– – S-7 Engine runs rough or is unstable
– – S-8 Engine lacks power
– – S-9 Exhaust smoke is black
– – S-10 Engine oil consumption is excessive
– – S-11 Oil becomes contaminated quickly
– – S-12 Fuel consumption is excessive
– – S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
– – S-14 Oil pressure drops
– – S-15 Fuel mixes into engine oil
– – S-16 Water mixes into engine oil (milky)
– – S-17 Coolant temperature rises too high (overheating)
– – S-18 Unusual noise is heard
– – S-19 Vibration is excessive
– – S-20 Air cannot be bled from fuel circuit

50 Disassembly and assembly
– General information on disassembly and assembly
– – How to read this manual
– – Coating materials list
– – Special tool list
– – Sketches of special tools
– Engine and cooling system
– – Removal and installation of fuel supply pump assembly
– – Removal and installation of fuel injector assembly
– – Removal and installation of engine hood assembly
– – Removal and installation of cylinder head assembly
– – Removal and installation of radiator assembly
– – Removal and installation of air aftercooler assembly
– – Removal and installation of hydraulic oil cooler assembly
– – Removal and installation of engine assembly
– – Removal and installation of belt for alternator and air conditioner compressor
– – Removal and installation of engine front oil seal assembly
– – Removal and installation of engine rear oil seal assembly
– – Removal and installation of cooling fan and fan motor assembly
– – Removal and installation of fuel tank assembly
– – Removal and installation of KCCV ventilator assembly
– – Removal and installation of KDOC muffler
– – Removal and installation of EGR cooler assembly
– – Removal and installation of EGR valve assembly
– Power train
– – Removal and installation of transfer assembly
– – Disassembly and assembly of transfer assembly
– – Removal and installation of parking brake assembly
– – Removal and installation of parking brake cylinder assembly
– – Disassembly and assembly of parking brake assembly
– – Removal and installation of front axle assembly
– – Removal and installation of rear axle assembly
– – Disassembly and assembly of axle housing assembly
– – Disassembly and assembly of differential assembly
– Undercarriage and frame
– – Removal and installation of center hinge pin
– – Removal and installation of counterweight assembly
– Hydraulic system
– – Removal and installation of HST pump and quadruple type gear pump assembly
– – Removal and installation of HST motor 1 assembly
– – Removal and installation of HST motor 2 assembly
– – Removal and installation of work equipment control valve assembly
– – Removal and installation of ECSS (Electronically Controlled Suspension System) valve assembly
– – Removal and installation of hydraulic tank assembly
– – Disassembly and assembly of hydraulic cylinder assembly
– Work equipment
– – Removal and installation of work equipment assembly
– Cab and its attachments
– – Removal and installation of operator’s cab and floor frame assembly
– – Removal and installation of operator’s cab glass (adhered glass)
– – Disassembly and assembly of operator’s seat
– – Removal and installation of air conditioner unit assembly
– – Removal and installation of air conditioner compressor assembly
– Electrical system
– – Removal and installation of machine monitor
– – Removal and installation of engine controller assembly
– – Removal and installation of HST controller assembly
– – Removal and installation of KOMTRAX terminal assembly

60 Maintenance standard
– Engine and cooling system
– – Engine mount and transfer mount
– – Damper
– – Cooling system
– – Cooling fan motor
– Power train
– – Drive shaft
– – Transfer
– – Axle
– – Differential
– – Limited slip differential
– – Final drive
– Steering system
– – Orbitrol valve
– – Steering cylinder
– – Steering column
– – Priority valve
– – Emergency steering valve
– Brake system
– – Charge valve
– – Slack adjuster
– – Brake
– – Parking brake
– Undercarriage and frame
– – Axle mount and center hinge pin
– Hydraulic system
– – Hydraulic tank
– – Work equipment control valve
– – PPC valve
– – ECSS valve
– – Quadruple gear pump
– Work equipment
– – Work equipment linkage
– – Bucket
– – Bucket positioner and boom kick-out
– – Work equipment cylinder

80 Appendix
– Air conditioner
– – Precautions for refrigerant
– – Air conditioner component
– – Configuration and function of refrigeration cycle
– – Outline of refrigeration cycle
– – Air conditioner unit
– – Functions of main components in air conditioner unit
– – Blower and intake unit
– – Compressor
– – Condenser
– – Receiver drier
– – Air conditioner control panel
– – Procedure for troubleshooting
– – Circuit diagram and arrangement of connector pins
– – System diagram
– – Details of air conditioner unit
– – Parts and connectors layout
– – Inspection by self-diagnosis function (displays diagnosis on the control panel)
– – Testing temperature control system
– – Testing FRESH/RECIRC air changeover
– – Testing evaporator temperature sensor
– – Testing relays
– – Troubleshooting chart 1
– – Troubleshooting chart 2
– – Information described in troubleshooting table
– – Troubleshooting for power supply system (Air conditioner does not operate)
– – Troubleshooting for compressor and refrigerant system (Air is not cooled)
– – Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
– – Troubleshooting for temperature control
– – Troubleshooting for FRESH/RECIRC air changeover
– – Connection of service tool
– – Troubleshooting by gauge pressure
– – Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
– – Handling of compressor oil

90 Diagrams and drawings
– Hydraulic diagrams and drawings
– – Symbols used in hydraulic circuit diagrams
– – Hydraulic circuit diagram
– Electrical diagrams and drawings
– – Symbols used in electric circuit diagrams
– – Electrical circuit diagram

Index

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