SEN06520-06
WHEEL LOADER
WA200 -6 Emerging Country Specification SERIAL NUMBERS
72001
and up
WHEEL LOADER WA200-6
Machine model
Serial number
WA200-6
72001 and up
00 Index and foreword
00
00
WA200-6
00-1
00 Index and foreword Index
Index and foreword
1
Index
1
00 Index and foreword Index and foreword .................................................................................................................................00-2 Foreword, safety and general information.............................................................................................00-11 Important safety notice ...................................................................................................................... 00-11 How to read the shop manual............................................................................................................ 00-18 Explanation of terms for maintenance standard ................................................................................ 00-20 Handling equipment of fuel system devices ...................................................................................... 00-22 Handling of intake system parts ........................................................................................................ 00-23 Handling of hydraulic equipment ....................................................................................................... 00-24 Method of disconnecting and connecting of push-pull type coupler .................................................. 00-26 Handling of electrical equipment ....................................................................................................... 00-29 How to read electric wire code .......................................................................................................... 00-37 Precautions when performing operation............................................................................................ 00-40 Practical use of KOMTRAX ............................................................................................................... 00-45 Standard tightening torque table ....................................................................................................... 00-46 List of Abbreviation ............................................................................................................................ 00-52 Conversion table................................................................................................................................ 00-56 01 Specifications Specification............................................................................................................................................01-3 Specification dimension drawing .........................................................................................................01-3 Specifications ......................................................................................................................................01-4 Weight table.........................................................................................................................................01-8 Table of fuel, coolant and lubricants.................................................................................................. 01-10 10 Structure, function and maintenance standard Engine and cooling system .....................................................................................................................10-4 Engine mount and transfer mount .......................................................................................................10-4 Damper................................................................................................................................................10-5 Cooling system ....................................................................................................................................10-6 Cooling system hydraulic piping diagram ............................................................................................10-7 Cooling fan motor ................................................................................................................................10-9 Power train ............................................................................................................................................ 10-17 Power train ........................................................................................................................................ 10-17 Power train system diagram .............................................................................................................. 10-18 Drive shaft ......................................................................................................................................... 10-20 HST hydraulic piping diagram ........................................................................................................... 10-21 HST pump ......................................................................................................................................... 10-22 HST motor ......................................................................................................................................... 10-30 Transfer ............................................................................................................................................. 10-36 Clutch solenoid valve......................................................................................................................... 10-47 Axle.................................................................................................................................................... 10-48 Differential ......................................................................................................................................... 10-50 Torque proportioning differential........................................................................................................ 10-55 Limited slip differential ....................................................................................................................... 10-58 Final drive .......................................................................................................................................... 10-62 Steering system .................................................................................................................................... 10-67 Steering piping diagram..................................................................................................................... 10-67 Steering column................................................................................................................................. 10-68 Priority valve ...................................................................................................................................... 10-69 Orbit-roll valve ................................................................................................................................... 10-72 00-2
WA200-6
00 Index and foreword Index
2-way restrictor valve ........................................................................................................................ 10-80 Cushion valve.................................................................................................................................... 10-81 Steering cylinder................................................................................................................................ 10-82 Emergency steering piping diagram.................................................................................................. 10-84 Emergency steering valve ................................................................................................................. 10-85 Steering relief valve........................................................................................................................... 10-88 Brake system ........................................................................................................................................ 10-89 Brake piping diagram ........................................................................................................................ 10-89 Charge valve ..................................................................................................................................... 10-90 Brake valve........................................................................................................................................ 10-94 Inching valve ..................................................................................................................................... 10-98 Accumulator (for brake)..................................................................................................................... 10-99 Slack adjuster.................................................................................................................................. 10-100 Brake ............................................................................................................................................... 10-102 Parking brake control ...................................................................................................................... 10-107 Parking brake .................................................................................................................................. 10-108 Undercarriage and frame .................................................................................................................... 10-110 Axle mount and center hinge pin..................................................................................................... 10-110 Hydraulic system................................................................................................................................. 10-116 Work equipment hydraulic piping diagram ...................................................................................... 10-116 Work equipment control lever linkage ............................................................................................. 10-118 Hydraulic tank.................................................................................................................................. 10-120 Quadruple gear pump ..................................................................................................................... 10-122 Work equipment control valve ......................................................................................................... 10-125 PPC valve........................................................................................................................................ 10-142 Lock valve ....................................................................................................................................... 10-150 Accumulator (for PPC circuit) .......................................................................................................... 10-151 Work equipment.................................................................................................................................. 10-152 Work equipment linkage.................................................................................................................. 10-152 Bucket ............................................................................................................................................. 10-154 Bucket positioner and boom kick-out .............................................................................................. 10-156 Work equipment cylinder................................................................................................................. 10-164 Cab and its attachments ..................................................................................................................... 10-167 Cab.................................................................................................................................................. 10-167 Air conditioner ................................................................................................................................. 10-169 Electrical system ................................................................................................................................. 10-181 Machine monitor system ................................................................................................................. 10-181 Machine monitor.............................................................................................................................. 10-185 Electrical system (HST controller system)....................................................................................... 10-206 HST controller ................................................................................................................................. 10-220 KOMTRAX system .......................................................................................................................... 10-222 Engine starting circuit ...................................................................................................................... 10-226 Engine stopping circuit .................................................................................................................... 10-228 Preheating circuit............................................................................................................................. 10-229 Engine output derating function....................................................................................................... 10-230 Automatic warm-up function............................................................................................................ 10-230 Parking brake circuit........................................................................................................................ 10-231 Max. traction switch......................................................................................................................... 10-233 Sensor ............................................................................................................................................. 10-234 20 Standard value table Standard service value table................................................................................................................... 20-3 Standard service value table for engine .............................................................................................. 20-3 Standard service value table for chassis............................................................................................. 20-4
WA200-6
00-3
00 Index and foreword Index
30 Testing and adjusting Related information on testing and adjusting ..........................................................................................30-4 Tools for testing, adjusting, and troubleshooting .................................................................................30-4 Sketches of special tools .....................................................................................................................30-9 Engine and cooling system ................................................................................................................... 30-10 Measuring engine speed ................................................................................................................... 30-10 Measuring exhaust gas color............................................................................................................. 30-12 Adjusting valve clearance.................................................................................................................. 30-13 Measuring compression pressure ..................................................................................................... 30-15 Measuring blowby pressure............................................................................................................... 30-18 Testing engine oil pressure ............................................................................................................... 30-19 Measuring intake air (boost) pressure ............................................................................................... 30-20 Handling fuel system equipment ....................................................................................................... 30-21 Releasing residual pressure in fuel system ....................................................................................... 30-21 Measuring fuel pressure .................................................................................................................... 30-22 Measuring fuel return rate and leakage............................................................................................. 30-24 Bleeding air from fuel circuit .............................................................................................................. 30-28 Checking leakage in fuel system ....................................................................................................... 30-29 Handling cylinder cut-out mode operation ......................................................................................... 30-30 Handling no-injection cranking operation .......................................................................................... 30-30 Handling controller voltage circuit...................................................................................................... 30-31 Check of muffler and muffler stack for looseness and damage......................................................... 30-31 Check of muffler function................................................................................................................... 30-32 Check of installed condition of cylinder head and manifolds ............................................................. 30-32 Check of engine piping for damage and looseness........................................................................... 30-33 Testing and adjusting air conditioner compressor belt tension.......................................................... 30-33 Replacing alternator belt.................................................................................................................... 30-34 Power train ............................................................................................................................................ 30-35 Testing and adjusting HST oil pressure............................................................................................. 30-35 Testing clutch control pressure.......................................................................................................... 30-39 Steering system .................................................................................................................................... 30-40 Testing steering wheel....................................................................................................................... 30-40 Testing and adjusting steering oil pressure ....................................................................................... 30-42 Bleeding air from steering circuit ....................................................................................................... 30-44 Brake system ........................................................................................................................................ 30-45 Measuring brake pedal ...................................................................................................................... 30-45 Testing and adjusting brake pedal linkage ........................................................................................ 30-46 Measuring brake performance........................................................................................................... 30-47 Testing and adjusting accumulator charge pressure......................................................................... 30-48 Testing wheel brake oil pressure....................................................................................................... 30-50 Testing wear of brake disc................................................................................................................. 30-53 Bleeding air from wheel brake circuit................................................................................................. 30-54 Releasing residual pressure in brake accumulator circuit ................................................................. 30-55 Testing parking brake performance................................................................................................... 30-56 Testing and adjusting parking brake control cable ............................................................................ 30-57 Hydraulic system................................................................................................................................... 30-58 Testing hydraulic fan ......................................................................................................................... 30-58 Testing and adjusting work equipment hydraulic pressure................................................................ 30-60 Testing work equipment PPC oil pressure ........................................................................................ 30-62 Bleeding air from hydraulic circuit...................................................................................................... 30-64 Releasing remaining pressure in hydraulic circuit ............................................................................. 30-65 Work equipment .................................................................................................................................... 30-66 Testing and adjusting bucket positioner ............................................................................................ 30-66 Testing and adjusting boom kick-out switch ...................................................................................... 30-68 Checking proximity switch operation pilot lamp.................................................................................30-69
00-4
WA200-6
This is the sample of the manual Click on the download link for complete manual
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00 Index and foreword Index
Cab and its attachments ....................................................................................................................... 30-70 Checking operating force of accelerator pedal.................................................................................. 30-70 Checking directional lever ................................................................................................................. 30-71 Measuring work equipment control lever........................................................................................... 30-72 Electrical system ................................................................................................................................... 30-73 Procedure for testing diodes ............................................................................................................. 30-73 Preparation work for troubleshooting for electric system .................................................................. 30-75 Starting KOMTRAX terminal operations............................................................................................ 30-79 Indicator lamps of KOMTRAX terminal ............................................................................................. 30-86 Adjusting machine monitor ................................................................................................................ 30-92 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor................ 30-93 Special functions of machine monitor (EMMS) ................................................................................. 30-95 Pm clinic.............................................................................................................................................. 30-146 Pm clinic inspection chart................................................................................................................ 30-146 40 Troubleshooting Related information on troubleshooting .................................................................................................. 40-7 Points to remember when performing troubleshooting........................................................................ 40-7 How to proceed in troubleshooting...................................................................................................... 40-9 Testing before troubleshooting.......................................................................................................... 40-11 Classification and procedures of troubleshooting.............................................................................. 40-12 Phenomena looking like troubles and troubleshooting Nos. ............................................................. 40-16 Information in troubleshooting table .................................................................................................. 40-18 Troubleshooting method for open circuit in wiring harness of pressure sensor system .................... 40-20 Connection table for connector pin numbers..................................................................................... 40-23 T- branch box and T- branch adapter table....................................................................................... 40-59 Fuse location ..................................................................................................................................... 40-63 Failure codes table ............................................................................................................................ 40-67 Troubleshooting by failure code (Display of code)................................................................................ 40-74 Failure code [2G40ZG] Brake : Low oil pressure .............................................................................. 40-74 Failure code [6091NX] HST filter : Clogging ..................................................................................... 40-76 Failure code [989FN1] Travel speed : Overrun alarm ....................................................................... 40-78 Failure code [AB00L6] Alternator R system : Hot short..................................................................... 40-80 Failure code [AB00MA] Alternator R system : Ground fault / Open circuit / Low charge level.......... 40-82 Failure code [B@BAZG] Engine : Low oil pressure .......................................................................... 40-84 Failure code [B@BCNS] Engine : Overheat...................................................................................... 40-85 Failure code [B@BCZK] Engine : Low coolant level ......................................................................... 40-86 Failure code [B@C6NS] Front brake : Oil temperature overheat...................................................... 40-88 Failure code [B@CRNS] HST : Oil temperature overheat ................................................................ 40-89 Failure code [CA111] Engine controller : Internal failure................................................................... 40-90 Failure code [CA115] Engine Ne and Bkup speed sensor : Error ..................................................... 40-91 Failure code [CA122] Charge air pressure sensor : High error ......................................................... 40-92 Failure code [CA123] Charge air pressure sensor : Low error.......................................................... 40-94 Failure code [CA131] Throttle sensor : High error............................................................................. 40-96 Failure code [CA132] Throttle sensor : Low error ............................................................................. 40-98 Failure code [CA144] Coolant temperature sensor : High error ...................................................... 40-100 Failure code [CA145] Coolant temperature sensor : Low error....................................................... 40-102 Failure code [CA153] Charge air temperature sensor : High error.................................................. 40-104 Failure code [CA154] Charge air temperature sensor : Low error .................................................. 40-106 Failure code [CA155] Charge air temperature : High speed derate ................................................ 40-108 Failure code [CA187] Sensor power supply 2 voltage : Low error .................................................. 40-110 Failure code [CA221] Ambient pressure sensor : High error........................................................... 40-112 Failure code [CA222] Ambient pressure sensor : Low error ........................................................... 40-114 Failure code [CA227] Sensor power supply 2 voltage : High error ................................................. 40-116 Failure code [CA234] Engine : Overspeed...................................................................................... 40-116 WA200-6
00-5
00 Index and foreword Index
Failure code [CA238] Ne Speed sensor : Power supply voltage error ............................................ 40-117 Failure code [CA271] IMV (IMA): Short circuit................................................................................. 40-118 Failure code [CA272] IMV (IMA): Open circuit ................................................................................ 40-120 Failure code [CA322] Injector #1 system : Open/Short circuit......................................................... 40-122 Failure code [CA324] Injector #3 system : Open/Short circuit......................................................... 40-124 Failure code [CA331] Injector #2 system : Open/Short circuit......................................................... 40-126 Failure code [CA332] Injector #4 system : Open/Short circuit......................................................... 40-128 Failure code [CA342] Engine controller : Data mismatching ........................................................... 40-130 Failure code [CA351] Injectors Drive Circuit : Error......................................................................... 40-131 Failure code [CA352] Sensor power supply 1 voltage : Low error .................................................. 40-132 Failure code [CA386] Sensor power supply voltage 1 : High error.................................................. 40-134 Failure code [CA428] Water-in-fuel sensor : High error .................................................................. 40-136 Failure code [CA429] Water-in-fuel sensor : Low error ................................................................... 40-138 Failure code [CA431] Idle validation switch : Error.......................................................................... 40-140 Failure code [CA432] Idle validation switch : Action error ............................................................... 40-143 Failure code [CA435] Engine oil pressure switch : Error ................................................................. 40-146 Failure code [CA441] Power supply voltage : Low error ................................................................. 40-148 Failure code [CA442] Power supply voltage : High error................................................................. 40-151 Failure code [CA449] Common rail pressure : High error 2 ............................................................ 40-152 Failure code [CA451] Common rail pressure sensor : High error.................................................... 40-154 Failure code [CA452] Common rail pressure sensor : Low error .................................................... 40-156 Failure code [CA488] Charge temperature : High torque derate..................................................... 40-158 Failure code [CA553] Common rail pressure : High error ............................................................... 40-159 Failure code [CA559] Supply Pump : Low rail pressure 1 ............................................................... 40-160 Failure code [CA689] Engine Ne speed sensor : Error ................................................................... 40-162 Failure code [CA731] Engine Bkup speed sensor : Phase error ..................................................... 40-164 Failure code [CA757] Engine controller : Lost of all data ................................................................ 40-165 Failure code [CA778] Engine Bkup speed sensor : Error................................................................ 40-166 Failure code [CA1633] KOMNET : Error ......................................................................................... 40-169 Failure code [CA2185] Throttle sensor power supply voltage : High error ...................................... 40-170 Failure code [CA2186] Throttle sensor power supply voltage : Low error....................................... 40-172 Failure code [CA2249] Supply pump : Low rail pressure 2 ............................................................. 40-174 Failure code [CA2311] IMV (IMA) Solenoid : Error.......................................................................... 40-175 Failure code [CA2555] Intake heater relay : Open circuit................................................................ 40-176 Failure code [CA2556] Intake heater relay : Short circuit ................................................................ 40-179 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short.............................................. 40-182 Failure code [D1B0KA] HST safety relay: Disconnection................................................................ 40-184 Failure code [D1B0KB] HST safety relay: Ground fault................................................................... 40-186 Failure code [D1B0KY] HST safety relay: Hot short........................................................................ 40-188 Failure code [D5ZHL6] IGN C system: Ground fault/ Disconnection............................................... 40-190 Failure code [DAF3KK] UNSW power supply: Ground fault/ Disconnection ................................... 40-194 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection................................... 40-197 Failure code [DAJ0KK] HST controller power supply: Low voltage................................................. 40-198 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality ...................................... 40-201 Failure code [DAJ1L4] HST controller main power supply line: Disconnection/Ground fault .......... 40-202 Failure code [DAJ1L6] HST controller main power supply line: Hot short....................................... 40-205 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage.......................................... 40-208 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short................................40-211 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault .................................................................................................................................................. 40-214 Failure code [DAJ5KX] Sensor 5V power supply: Out of input range ............................................. 40-217 Failure code [DAJ9KQ] HST controller : Disagreement in model selection..................................... 40-219 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ....................................... 40-220 Failure code [DAJRMA] HST controller: Disagreement in option selection..................................... 40-227 Failure code [DB2RKR] Engine controller CAN-NET signal: Disconnection ................................... 40-228 Failure code [DD1NL4] Fan Auto Reverse Switch Signal : Abnormality ......................................... 40-234 00-6
WA200-6
00 Index and foreword Index
Failure code [DD1NLD] Fan Reverse Switch Signal: Abnormal...................................................... 40-237 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short .......................... 40-240 Failure code [DDB6KB] Parking brake indicator signal: Ground fault ............................................. 40-244 Failure code [DDB6KZ] Parking brake indicator signal or parking brake reminder signal : Failure. 40-247 Failure code [DDB6L0] Parking brake reminder signal: Ground fault ............................................. 40-250 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short............................ 40-253 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ................... 40-258 Failure code [DDD7KY] Travel speed control dial signal: Hot short................................................ 40-260 Failure code [DDE5MA] Emergency steering operation switch: Disconnection .............................. 40-262 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault..................................................... 40-264 Failure code [DDK6KY] FNR lever: Hot short ................................................................................. 40-268 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering).................. 40-270 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault .............. 40-272 Failure code [DF10KB] Travel speed range selector switch: Hot short........................................... 40-277 Failure code [DGH1KX] HST oil temperature sensor: Ground fault ................................................ 40-282 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault.............................................. 40-284 Failure code [DGR2KZ] Brake oil temperature sensor : Disconnection/Hot short........................... 40-286 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault .............................. 40-288 Failure code [DHH1KY] HST oil pressure sensor: Hot short ........................................................... 40-290 Failure code [DHTCL6] HST filter clogging sensor: Functional defect ............................................ 40-292 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short................................................ 40-294 Failure code [DLT3KX] Travel speed sensor B: Abnormality .......................................................... 40-296 Failure code [DLT4KX] Travel speed sensor A: Abnormality .......................................................... 40-302 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality ................................................... 40-304 Failure code [DV00KY] Alarm buzzer: Hot short ............................................................................. 40-306 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault.......................................... 40-308 Failure code [DW26KY] Motor 2 solenoid: Hot short....................................................................... 40-310 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short..................................................... 40-312 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault ........................ 40-314 Failure code [DX16KA] Fan EPC solenoid: Disconnection ............................................................. 40-316 Failure code [DX16KB] Fan EPC solenoid: Ground fault ................................................................ 40-317 Failure code [DX16KY] Fan EPC solenoid: Hot short ..................................................................... 40-318 Failure code [DX19KA] Motor 1 solenoid: Disconnection................................................................ 40-320 Failure code [DX19KB] Motor 1 solenoid: Ground fault .................................................................. 40-322 Failure code [DX19KY] Motor 1 solenoid: Hot short........................................................................ 40-324 Failure code [DX20KA] Clutch EPC solenoid: Disconnection ......................................................... 40-326 Failure code [DX20KB] Clutch EPC solenoid: Ground fault ............................................................ 40-328 Failure code [DX20KY] Clutch EPC solenoid: Hot short ................................................................. 40-330 Failure code [DXH7KB] Reverse solenoid : Ground fault................................................................ 40-332 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short .............................................. 40-334 Failure code [DXH8KB] Forward solenoid : Ground fault................................................................ 40-336 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................... 40-338 Failure code [J141N1] Steering pump: Overrun alarm.................................................................... 40-340 Failure code [M100N1] HST pump: Overrun alarm......................................................................... 40-340 Failure code [M400N1] Motor 1: Overrun alarm.............................................................................. 40-341 Troubleshooting of electrical system (E-mode)................................................................................... 40-342 E-1 Engine does not start................................................................................................................ 40-342 E-2 Preheater does not operate normally ....................................................................................... 40-350 E-3 When starting switch is turned to ON position, nothing is displayed on machine monitor........ 40-355 E-4 Travel speed is not displayed correctly..................................................................................... 40-359 E-5 Travel speed is low or high ....................................................................................................... 40-360 E-6 Boom kick-out does not work or is not reset............................................................................. 40-363 E-7 Bucket positioner does not work or is not reset ........................................................................ 40-367 E-8 Boom FLOAT holding does not work or is not reset ................................................................. 40-371 E-9 Directional selection does not work normally............................................................................ 40-377 E-10 Wipers do not operate ............................................................................................................ 40-382 WA200-6
00-7
00 Index and foreword Index
E-11 Window washer does not operate........................................................................................... 40-388 E-12 Headlamp, clearance lamp, tail lamp or license-plate lamp does not light up or does not go out .................................................................................................................................................. 40-392 E-13 Working lamp does not light up or does not go out................................................................. 40-402 E-14 Turn signal and hazard lamp do not light up or do not go out................................................. 40-408 E-15 Stop lamp does not light up or remains lighting up ................................................................. 40-418 E-16 Backup lamp does not light or it keeps lighting up.................................................................. 40-421 E-17 Backup alarm does not sound or does not stop sounding ...................................................... 40-424 E-18 Horn does not sound or does not stop sounding .................................................................... 40-426 E-19 Alarm buzzer does not sound or does not stop sounding....................................................... 40-428 E-20 Troubleshooting of air conditioner........................................................................................... 40-430 E-21 KOMTRAX system does not operate normally ....................................................................... 40-452 Troubleshooting of hydraulic and mechanical system (H-mode) ........................................................ 40-456 Method of using troubleshooting chart ............................................................................................ 40-456 Failure code and cause table .......................................................................................................... 40-458 H-1 The machine does not start ...................................................................................................... 40-460 H-2 The travel speed is slow ........................................................................................................... 40-461 H-3 The traction force is weak......................................................................................................... 40-462 H-4 Engine stalls when traveling or engine speed drops excessively ............................................. 40-463 H-5 Speed range is not shifted ........................................................................................................ 40-464 H-6 The steering wheel does not turn ............................................................................................. 40-465 H-7 The steering wheel is heavy ..................................................................................................... 40-466 H-8 Steering wheel shakes or jerks................................................................................................. 40-467 H-9 Machine deviates naturally to one side when traveling ............................................................ 40-467 H-10 The brake does not work or does not work well ..................................................................... 40-468 H-11 The brake is not released or is dragged ................................................................................. 40-469 H-12 The boom does not rise or lower ............................................................................................ 40-470 H-13 The boom moves slowly or the lift arm rising force is insufficient ........................................... 40-471 H-14 When rising, the boom comes to move slowly at specific height............................................ 40-472 H-15 The lift cylinder cannot hold down the bucket (The bucket rises in the air) ............................ 40-472 H-16 Hydraulic drifts of the boom are large..................................................................................... 40-472 H-17 The boom wobbles during operation ...................................................................................... 40-472 H-18 When the control lever is switched from “HOLD” to “RAISE,” the boom falls temporarily ...... 40-473 H-19 The bucket does not tilt back .................................................................................................. 40-474 H-20 The bucket moves slowly or the tilting-back force is insufficient............................................. 40-475 H-21 The bucket comes to operate slowly in the midst of tilting-back............................................. 40-476 H-22 The bucket cylinder cannot hold down the bucket.................................................................. 40-476 H-23 Hydraulic drifts of the bucket occur often................................................................................ 40-476 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”).... 40-476 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ........ 40-477 H-26 The control levers of the boom and bucket do not move smoothly and heavy....................... 40-477 H-27 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) .. 40-478 Troubleshooting of engine (S-mode)................................................................................................... 40-479 Method of using troubleshooting charts........................................................................................... 40-479 S-1 Starting performance is poor..................................................................................................... 40-482 S-2 Engine does not start ................................................................................................................ 40-483 S-3 Engine does not pick up smoothly ............................................................................................ 40-486 S-4 Engine stops during operations ................................................................................................ 40-487 S-5 Engine does not rotate smoothly .............................................................................................. 40-488 S-6 Engine lacks output (or lacks power) ........................................................................................ 40-489 S-7 Exhaust smoke is black (incomplete combustion) .................................................................... 40-490 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................... 40-491 S-9 Oil becomes contaminated quickly ........................................................................................... 40-492 S-10 Fuel consumption is excessive ............................................................................................... 40-493 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ..................................... 40-494 S-12 Oil pressure drops................................................................................................................... 40-495 00-8
WA200-6
00 Index and foreword Index
S-13 Oil level rises (Entry of coolant or fuel) ................................................................................... 40-496 S-14 Coolant temperature becomes too high (overheating) ........................................................... 40-497 S-15 Abnormal noise is made ......................................................................................................... 40-498 S-16 Vibration is excessive ............................................................................................................. 40-499 50 Disassembly and assembly General information on disassembly and assembly ............................................................................... 50-3 How to read this manual...................................................................................................................... 50-3 Coating materials list ........................................................................................................................... 50-5 Special tool list .................................................................................................................................... 50-9 Sketches of special tools................................................................................................................... 50-13 Engine and cooling system ................................................................................................................... 50-22 Removal and installation of fuel supply pump assembly................................................................... 50-22 Removal and installation of fuel injector assembly............................................................................ 50-26 Removal and installation of cylinder head assembly......................................................................... 50-34 Removal and installation engine hood assembly .............................................................................. 50-48 Removal and installation of radiator .................................................................................................. 50-52 Removal and installation of air aftercooler ........................................................................................ 50-55 Removal and installation of hydraulic oil cooler assembly ................................................................ 50-57 Removal and installation of engine assembly ................................................................................... 50-59 Removal and installation of engine front oil seal assembly............................................................... 50-66 Removal and installation of engine rear oil seal assembly................................................................ 50-70 Removal and installation of cooling fan and fan motor assembly ..................................................... 50-73 Removal and installation of fuel tank assembly ................................................................................ 50-76 Power train............................................................................................................................................ 50-78 Removal and installation of transfer assembly.................................................................................. 50-78 Disassembly and assembly of transfer assembly ............................................................................. 50-82 Removal and installation of parking brake assembly ...................................................................... 50-101 Disassembly and assembly of parking brake assembly.................................................................. 50-103 Removal and installation of front axle assembly ............................................................................. 50-108 Removal and installation of rear axle assembly .............................................................................. 50-110 Disassembly and assembly of axle housing assembly ................................................................... 50-113 Disassembly and assembly of differential assembly ....................................................................... 50-121 Undercarriage and frame .................................................................................................................... 50-148 Removal and installation of center hinge pin................................................................................... 50-148 Removal and installation of counterweight assembly...................................................................... 50-157 Hydraulic system................................................................................................................................. 50-159 Removal and installation of HST pump and quadruple gear pump assembly................................. 50-159 Removal and installation of HST motor 1 assembly........................................................................ 50-163 Removal and installation of HST motor 2 assembly........................................................................ 50-165 Removal and installation of work equipment control valve assembly ............................................. 50-167 Removal and installation of hydraulic tank ...................................................................................... 50-169 Disassembly and assembly of hydraulic cylinder assembly............................................................ 50-171 Work equipment.................................................................................................................................. 50-175 Removal and installation of work equipment assembly................................................................... 50-175 Cab and its attachments ..................................................................................................................... 50-182 Removal and installation of operator's cab and floor frame assembly ............................................ 50-182 Removal and installation of operator's cab glass (Stuck glass) ...................................................... 50-187 Removal and installation of operator's seat assembly .................................................................... 50-195 Removal and installation of air conditioner unit............................................................................... 50-196 Electrical system ................................................................................................................................. 50-201 Removal and installation of monitor panel ...................................................................................... 50-201 Removal and installation of engine controller assembly ................................................................. 50-203 Removal and installation of HST controller assembly ..................................................................... 50-205 Removal and installation of KOMTRAX terminal (ORBCOMM) assembly...................................... 50-206 WA200-7 (04)
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00 Index and foreword Index
Removal and installation of KOMTRAX terminal (GPRS) assembly ............................................... 50-207 90 Diagrams and drawings Hydraulic diagrams and drawings ...........................................................................................................90-3 Symbols used in hydraulic circuit diagrams.........................................................................................90-3 Hydraulic circuit diagram .....................................................................................................................90-5 Electrical diagrams and drawings ...........................................................................................................90-7 Symbols used in electric circuit diagrams............................................................................................90-7 Electrical circuit diagram.................................................................................................................. 90-11 Electrical circuit diagram for CIS ..................................................................................................... 90-27 Electrical circuit diagram of engine and HST................................................................................... 90-37 Connector list and stereogram ........................................................................................................ 90-39 Connector list and stereogram (CIS specification) .......................................................................... 90-41 Index ...........................................................................................................................................................
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WA200-6
00 Index and foreword Important safety notice
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1. Wind up the rope slowly until the wire rope tensions. When putting your hands on the wire ropes, do not grasp them but press them down from above. If you grasp them, your fingers may be caught.
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WA200-6
00-13