WA200-7 Komatsu Service Manual PDF Download

SEN06503-14

WHEEL LOADER SERIAL NUMBERS

80001

and up

WHEEL LOADER WA200-7

Machine model

Serial number

WA200-7

80001 and up

00 Index and foreword

WA200-7

00-1

00 Index and foreword Index

Index and foreword Index 00 Index and foreword Index and foreword .................................................................................................................................00-2 Foreword, safety and general information............................................................................................. 00-14 Important safety notice ...................................................................................................................... 00-14 How to read the shop manual............................................................................................................ 00-21 Explanation of terms for maintenance standard ................................................................................ 00-23 Handling equipment of fuel system devices ...................................................................................... 00-25 Handling of intake system parts ........................................................................................................ 00-26 Handling of hydraulic equipment ....................................................................................................... 00-27 Method of disconnecting and connecting of push-pull type coupler .................................................. 00-29 Handling of electrical equipment ....................................................................................................... 00-32 How to read electric wire code .......................................................................................................... 00-40 Precautions when performing operation............................................................................................ 00-43 Practical use of KOMTRAX ............................................................................................................... 00-48 Standard tightening torque table ....................................................................................................... 00-49 List of Abbreviation ............................................................................................................................ 00-55 Conversion table................................................................................................................................ 00-59 01 Specifications Specifications ..........................................................................................................................................01-4 Specification dimension drawing .........................................................................................................01-4 Specifications ......................................................................................................................................01-6 Weight table....................................................................................................................................... 01-14 Table of fuel, coolant, and lubricants................................................................................................. 01-18 10 Structure and function Engine and cooling system .....................................................................................................................10-4 VFT......................................................................................................................................................10-4 EGR system piping drawing ................................................................................................................10-8 EGR system circuit diagram .............................................................................................................. 10-10 EGR valve ......................................................................................................................................... 10-12 EGR cooler ........................................................................................................................................ 10-14 KCCV layout drawing ........................................................................................................................ 10-16 KCCV ventilator ................................................................................................................................. 10-19 KDOC muffler .................................................................................................................................... 10-23 Damper.............................................................................................................................................. 10-25 Cooling system .................................................................................................................................. 10-26 Cooling system hydraulic piping diagram .......................................................................................... 10-27 Cooling fan motor .............................................................................................................................. 10-28 Power train ............................................................................................................................................ 10-37 Power train ........................................................................................................................................ 10-37 Power train system diagram .............................................................................................................. 10-38 Drive shaft ......................................................................................................................................... 10-40 HST hydraulic piping diagram ........................................................................................................... 10-41 HST pump ......................................................................................................................................... 10-42 HST motor ......................................................................................................................................... 10-50 Transfer ............................................................................................................................................. 10-56 Clutch solenoid valve......................................................................................................................... 10-62 Axle.................................................................................................................................................... 10-63 Differential ......................................................................................................................................... 10-65 Torque proportioning differential........................................................................................................ 10-68 00-2

WA200-7

00 Index and foreword Index

Limited slip differential....................................................................................................................... 10-69 Final drive.......................................................................................................................................... 10-72 Steering system .................................................................................................................................... 10-75 Steering piping diagram .................................................................................................................... 10-75 Orbitrol valve ..................................................................................................................................... 10-76 Steering column ................................................................................................................................ 10-84 Priority valve...................................................................................................................................... 10-85 Emergency steering valve ................................................................................................................. 10-88 Brake system ........................................................................................................................................ 10-91 Brake piping diagram ........................................................................................................................ 10-91 Brake valve........................................................................................................................................ 10-92 Charge valve ..................................................................................................................................... 10-96 Accumulator (for brake)................................................................................................................... 10-100 Slack adjuster.................................................................................................................................. 10-101 Brake ............................................................................................................................................... 10-103 Parking brake control ...................................................................................................................... 10-106 Parking brake .................................................................................................................................. 10-107 Parking brake cylinder..................................................................................................................... 10-108 Parking brake solenoid valve .......................................................................................................... 10-109 Inching valve ................................................................................................................................... 10-111 Undercarriage and frame .................................................................................................................... 10-112 Axle mount and center hinge pin..................................................................................................... 10-112 Hydraulic system................................................................................................................................. 10-114 Hydraulic component layout ............................................................................................................ 10-114 Work equipment control lever linkage ............................................................................................. 10-116 Hydraulic tank.................................................................................................................................. 10-117 Accumulator (for PPC circuit) .......................................................................................................... 10-119 Work equipment control valve ......................................................................................................... 10-120 PPC valve........................................................................................................................................ 10-133 Attachment EPC valve .................................................................................................................... 10-139 Work equipment lock solenoid valve ............................................................................................... 10-140 ECSS valve ..................................................................................................................................... 10-141 Accumulator (for ECSS) .................................................................................................................. 10-143 2-way restrictor valve ...................................................................................................................... 10-144 Cushion valve.................................................................................................................................. 10-145 Accumulator (for oil cooler circuit) ................................................................................................... 10-146 Quadruple gear pump ..................................................................................................................... 10-147 Quick coupler solenoid valve........................................................................................................... 10-148 Work equipment.................................................................................................................................. 10-149 Work equipment linkage.................................................................................................................. 10-149 Bucket ............................................................................................................................................. 10-151 Bucket positioner and boom kick-out .............................................................................................. 10-152 Cab and its attachments ..................................................................................................................... 10-158 Cab.................................................................................................................................................. 10-158 Electrical system ................................................................................................................................. 10-159 Machine monitor system ................................................................................................................. 10-159 Machine monitor.............................................................................................................................. 10-164 Electrical system (HST controller system)....................................................................................... 10-186 System component parts................................................................................................................. 10-202 HST controller ................................................................................................................................. 10-208 ECSS............................................................................................................................................... 10-212 KOMTRAX system .......................................................................................................................... 10-214 Engine starting circuit ...................................................................................................................... 10-217 Engine stopping circuit .................................................................................................................... 10-219 Preheating system........................................................................................................................... 10-220 Automatic preheating system .......................................................................................................... 10-221 WA200-7

00-3

00 Index and foreword Index

Manual preheating system .............................................................................................................. 10-221 Engine output limit function ............................................................................................................. 10-222 Automatic warm-up function ............................................................................................................ 10-222 Parking brake control system .......................................................................................................... 10-223 Multi-function mono-lever ................................................................................................................ 10-227 Sensor ............................................................................................................................................. 10-229 20 Standard value table Standard value table ............................................................................................................................... 20-3 Standard value table for engine...........................................................................................................20-3 Standard value table for machine........................................................................................................20-5 30 Testing and adjusting Related information on testing and adjusting ..........................................................................................30-4 Tools for testing and adjusting.............................................................................................................30-4 Engine and cooling system .....................................................................................................................30-7 Testing and adjusting engine speed....................................................................................................30-7 Testing exhaust gas temperature ........................................................................................................30-9 Testing exhaust gas color................................................................................................................ .30-10 Testing and adjusting valve clearance ............................................................................................ .30-12 Testing compression pressure ........................................................................................................ .30-14 Testing blowby pressure.................................................................................................................. .30-17 Testing engine oil pressure ............................................................................................................. .30-18 Testing boost pressure .................................................................................................................... .30-19 Handling equipment of fuel system devices .................................................................................... .30-21 Releasing remaining pressure from fuel system ............................................................................. .30-21 Visual check inside of EGR valve.................................................................................................. 30-21-1 Clean inside of EGR valve............................................................................................................. 30-21-2 Testing fuel pressure ....................................................................................................................... .30-22 Testing fuel discharge, return and leakage ..................................................................................... .30-27 Bleeding air from fuel system .......................................................................................................... .30-32 Testing fuel circuit for leakage......................................................................................................... .30-34 Handling cylinder cutout mode operation ........................................................................................ .30-35 Handling no-injection cranking operation ........................................................................................ .30-35 Testing KDPF and muffler stack for looseness and damage .......................................................... .30-36 Testing KDOC function.................................................................................................................... .30-36 Testing installed condition of cylinder heads and manifolds............................................................ .30-37 Testing engine piping for damage and looseness ........................................................................... .30-37 Testing and adjusting air conditioner compressor belt tension........................................................ .30-38 Testing and replacing alternator belt ............................................................................................... .30-39 Testing and replacing auto-tensioner .............................................................................................. .30-41 Power train ............................................................................................................................................30-43 Testing oil leakage from axle final drive .......................................................................................... .30-43 Testing drive shaft for looseness, backlash, and damage............................................................... .30-44 Testing accelerator pedal ................................................................................................................ .30-45 Testing and adjusting HST oil pressure........................................................................................... .30-47 Testing transfer clutch control pressure .......................................................................................... .30-52 Steering system ....................................................................................................................................30-53 Testing directional lever................................................................................................................... .30-53 Testing and adjusting steering wheel .............................................................................................. .30-54 Testing work equipment control lever.............................................................................................. .30-56 Testing and adjusting steering circuit oil pressure........................................................................... .30-57 Bleeding air from steering circuit ..................................................................................................... .30-59 Brake system ...................................................................................................................................... .30-60 00-4

WA200-7

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00 Index and foreword Index

Testing brake pedal......................................................................................................................... .30-60 Testing and adjusting brake pedal and linkage ............................................................................... .30-61 Testing braking performance........................................................................................................... .30-62 Testing and adjusting accumulator charge pressure....................................................................... .30-63 Testing wheel brake oil pressure..................................................................................................... .30-65 Testing lowering of wheel brake pressure....................................................................................... .30-66 Testing wear of wheel brake disc .................................................................................................... .30-69 Bleeding air from wheel brake circuit .............................................................................................. .30-70 Releasing remaining pressure in brake accumulator circuit............................................................ .30-71 Testing parking brake performance................................................................................................. .30-72 Testing parking brake release pressure .......................................................................................... .30-73 Method of releasing parking brake manually................................................................................... .30-74 Hydraulic system...................................................................................................................................30-75 Testing and adjusting cooling fan speed ......................................................................................... .30-75 Testing cooling fan pump circuit oil pressure ....................................................................................30-76 Testing work equipment PPC oil pressure ........................................................................................30-77 Testing and adjusting work equipment oil pressure .......................................................................... 30-78 Bleeding air from each part ...............................................................................................................30-79 Releasing remaining pressure in hydraulic circuit ............................................................................. 30-80 Work equipment....................................................................................................................................30-81 Testing and adjusting bucket positioner ............................................................................................30-81 Testing and adjusting boom kick-out switch......................................................................................30-82 Checking the proximity switch working pilot lamp .............................................................................30-83 Electrical system ...................................................................................................................................30-85 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor................30-85 Special functions of machine monitor................................................................................................30-87 KOMTRAX terminal start-up procedure .......................................................................................... 30-141 Lamp indication of KOMTRAX terminal........................................................................................... 30-144 Handling voltage circuit of controller ............................................................................................... 30-148 Test diodes...................................................................................................................................... 30-149 Pm Clinic............................................................................................................................................. 30-150 Pm Clinic service............................................................................................................................. 30-150 40 Troubleshooting Related information on troubleshooting ..................................................................................................40-9 Points to remember when performing troubleshooting........................................................................40-9 How to proceed in troubleshooting.................................................................................................... 40-11 Checks before troubleshooting.......................................................................................................... 40-13 Check procedure before troubleshooting .......................................................................................... 40-15 Preparation for troubleshooting of electrical system ......................................................................... 40-33 Classification and procedures of troubleshooting.............................................................................. 40-38 Symptom and troubleshooting No. .................................................................................................... 40-42 Information described in troubleshooting table.................................................................................. 40-44 Procedure for troubleshooting of open circuit in wiring harness of pressure sensor system ............ 40-46 Connector list and layout................................................................................................................... 40-48 Connection table of connector by No. of pins.................................................................................... 40-61 T-box and T-adapter list .................................................................................................................... 40-98 Fuse location table .......................................................................................................................... 40-102 Failure code list ............................................................................................................................... 40-105 Troubleshooting by failure code (Display of code).............................................................................. 40-113 Failure code [2F00MB] Malfunction of Parking Brake ..................................................................... 40-113 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)....................................................... 40-115 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....................................................... 40-117 Failure code [6091NX] HST Filter Clogging .................................................................................... 40-119 Failure code [7RHYKA] Open Circuit of Fan Motor EPC Solenoid Output...................................... 40-121 WA200-7

00-5

00 Index and foreword Index

Failure code [7RHYKB] Ground Fault of Fan Motor EPC Solenoid Output..................................... 40-123 Failure code [7RHYKY] Hot Short of Fan Motor EPC Solenoid Output........................................... 40-125 Failure code [989FN1] Travel Speed Overrun Alarm ...................................................................... 40-127 Failure code [AB00L6] Discharge of Alternator R Terminal............................................................. 40-128 Failure code [AB00MA] Ground Fault or Open Circuit of Battery Relay Status Signal Line, or Insufficient Battery Charging ....................................................................................................................... 40-130 Failure code [B@BAZG] Engine Oil Pressure Low ......................................................................... 40-132 Failure code [B@BCNS] Engine Water Overheat ........................................................................... 40-133 Failure code [B@BCZK] Engine Coolant Level Low ....................................................................... 40-134 Failure code [B@C6NS] Front Brake Oil Temperature Overheat (This Alarm) ............................... 40-136 Failure code [B@CRNS] HST Oil Temperature Overheat............................................................... 40-137 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................ 40-138 Failure code [CA122] Charge Air Pressure Sensor High Error ....................................................... 40-139 Failure code [CA123] Charge Air Pressure Sensor Low Error ........................................................ 40-141 Failure code [CA131] Throttle Sensor High Error............................................................................ 40-143 Failure code [CA132] Throttle Sensor Low Error............................................................................. 40-145 Failure code [CA144] Coolant Temperature Sensor High Error ...................................................... 40-147 Failure code [CA145] Coolant Temperature Sensor Low Error....................................................... 40-149 Failure code [CA153] Charge Air Temperature Sensor High Error ................................................. 40-151 Failure code [CA154] Chg Air Temp Sensor Low Error................................................................... 40-153 Failure code [CA187] Sensor 2 Supply Voltage Low Error.............................................................. 40-155 Failure code [CA221] Ambient Pressure Sensor High Error ........................................................... 40-157 Failure code [CA222] Ambient Pressure Sensor Low Error ............................................................ 40-159 Failure code [CA227] Sensor 2 Supply Voltage High Error............................................................. 40-161 Failure code [CA234] Engine Overspeed ........................................................................................ 40-162 Failure code [CA238] Ne Speed Sensor Supply Volt Error ............................................................. 40-163 Failure code [CA239] Ne Speed Sens Supply Volt High Error ........................................................ 40-164 Failure code [CA271] IMV/PCV1 Short Error .................................................................................. 40-165 Failure code [CA272] IMV/PCV1 Open Error .................................................................................. 40-167 Failure code [CA295] Ambient Press Sens In Range Error............................................................. 40-169 Failure code [CA322] Injector #1 (L#1) Open/Short Error ............................................................... 40-170 Failure code [CA324] Injector #3 (L#3) Open/Short Error ............................................................... 40-172 Failure code [CA331] Injector #2 (L#2) Open/Short Error ............................................................... 40-174 Failure code [CA332] Injector #4 (L#4) Open/Short Error ............................................................... 40-176 Failure code [CA343] Engine Controller Internal Failure ................................................................. 40-178 Failure code [CA351] Injectors Drive Circuit Error........................................................................... 40-179 Failure code [CA352] Sensor 1 Supply Voltage Low Error.............................................................. 40-180 Failure code [CA356] Mass Air Flow Sensor High Error ................................................................. 40-182 Failure code [CA357] Mass Air Flow Sensor Low Error .................................................................. 40-184 Failure code [CA386] Sensor 1 Supply Voltage High Error............................................................. 40-186 Failure code [CA428] Water in Fuel Sensor High Error................................................................... 40-187 Failure code [CA429] Water in Fuel Sensor Low Error ................................................................... 40-189 Failure code [CA431] Idle Validation Sw Error ................................................................................ 40-191 Failure code [CA432] Idle Validation Process Error ........................................................................ 40-194 Failure code [CA435] Engine Oil Pressure Sw Error....................................................................... 40-196 Failure code [CA441] Battery Voltage Low Error............................................................................. 40-197 Failure code [CA442] Battery Voltage High Error............................................................................ 40-199 Failure code [CA449] Rail Press Very High Error............................................................................ 40-200 Failure code [CA451] Common Rail Pressure Sensor High Error................................................... 40-201 Failure code [CA452] Common Rail Pressure Sensor Low Error.................................................... 40-203 Failure code [CA466] KVGT Motor Driver Position Error ................................................................ 40-205 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................... 40-207 Failure code [CA515] Rail Pressure Sensor Sup Volt High Error.................................................... 40-208 Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error..................................................... 40-210 Failure code [CA553] Common Rail Pressure High Error 1 ............................................................ 40-212 Failure code [CA555] Crankcase Press High Error 1 ...................................................................... 40-213 00-6

WA200-7

00 Index and foreword Index

Failure code [CA556] Crankcase Press High Error 2...................................................................... 40-214 Failure code [CA559] Rail Press Low Error 1.................................................................................. 40-215 Failure code [CA689] Engine Ne Speed Sensor Error .................................................................... 40-218 Failure code [CA691] Intake Air Temp Sens High Error.................................................................. 40-220 Failure code [CA692] Intake Air Temp Sens Low Error .................................................................. 40-222 Failure code [CA697] ECM Internal Temperature Sensor High Error ............................................. 40-224 Failure code [CA698] EMC Internal Temperature Sensor Low Error .............................................. 40-225 Failure code [CA731] Engine Bkup Speed Sensor Phase Error ..................................................... 40-226 Failure code [CA778] Engine Bkup Speed Sensor Error ................................................................ 40-228 Failure code [CA1117] Persistent Data Lost Error .......................................................................... 40-233 Failure code [CA1695] Sensor 5 Supply Voltage High Error........................................................... 40-234 Failure code [CA1696] Sensor 5 Supply Voltage Low Error ........................................................... 40-235 Failure code [CA1843] Crankcase Press Sens High Error.............................................................. 40-236 Failure code [CA1844] Crankcase Press Sens Low Error .............................................................. 40-238 Failure code [CA1896] EGR Valve Stuck Error............................................................................... 40-240 Failure code [CA1942] Crankcase Press Sens In-Range Error ...................................................... 40-241 Failure code [CA1961] EGR Motor Driver IC Over Temp Error ...................................................... 40-242 Failure code [CA2185] Throttle Sensor Supply Voltage High Error ................................................ 40-243 Failure code [CA2186] Throttle Sensor Supply Voltage Low Error ................................................. 40-245 Failure code [CA2249] Rail Press Low Error 2................................................................................ 40-247 Failure code [CA2272] EGR Valve Position Sensor Low Error ....................................................... 40-248 Failure code [CA2311] IMV Solenoid Error ..................................................................................... 40-250 Failure code [CA2349] EGR Valve Solenoid Open Circuit Error..................................................... 40-251 Failure code [CA2353] EGR Valve Solenoid Short Circuit Error ..................................................... 40-253 Failure code [CA2357] EGR Valve Servo Error .............................................................................. 40-255 Failure code [CA2373] Exhaust Manifold Pressure Sensor High Error........................................... 40-256 Failure code [CA2374] Exhaust Manifold Pressure Sensor Low Error............................................ 40-258 Failure code [CA2375] EGR Orifice Temperature Sensor High Error ............................................. 40-260 Failure code [CA2376] EGR Orifice Temperature Sensor Low Error.............................................. 40-262 Failure code [CA2554] Exhaust Manifold Pressure Sensor In-Range Error ................................... 40-264 Failure code [CA2555] Grid Heater Relay Voltage Low Error ......................................................... 40-265 Failure code [CA2556] Grid Heater Relay Voltage High Error ........................................................ 40-267 Failure code [CA2961] EGR Orifice Temperature High Error 1 ...................................................... 40-269 Failure code [CA2973] Charge Air Pressure Sensor In-Range Error.............................................. 40-270 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error................................................. 40-271 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ................................................. 40-273 Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error ................................................ 40-275 Failure code [CA3741] Common Rail Pressure Valve Trip Error .................................................... 40-277 Failure code [CA3918] KVGT Stuck Error....................................................................................... 40-278 Failure code [CA3919] KVGT Motor Driver IC Over Temperature Error ......................................... 40-279 Failure code [CA3921] KVGT Servo Error 2 ................................................................................... 40-280 Failure code [CA3922] KVGT Motor Driver Open Error .................................................................. 40-281 Failure code [CA3923] KVGT Motor Driver Short Error .................................................................. 40-283 Failure code [D110L4] Disconnection or Short to Ground of Battery Relay Signal Line ................. 40-285 Failure code [D160KA] Disconnection of Backup Lamp Relay Output............................................ 40-287 Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ............................................. 40-289 Failure code [D160KY] Hot Short of Backup Lamp Relay Output ................................................... 40-291 Failure code [D191KA] Disconnection of Neutral Output Relay ...................................................... 40-293 Failure code [D191KB] Ground Fault of Neutral Output Relay........................................................ 40-295 Failure code [D191KY] Hot Short of Neutral Output Relay ............................................................. 40-297 Failure code [D192KA] Disconnection of ECSS Solenoid Relay..................................................... 40-299 Failure code [D192KB] Ground Fault of ECSS Solenoid Relay ...................................................... 40-301 Failure code [D192KY] Hot Short of ECSS Solenoid Relay ............................................................ 40-303 Failure code [D1B0KA] Disconnection of HST Safety Relay........................................................... 40-305 Failure code [D1B0KB] Ground Fault of HST Safety Relay ............................................................ 40-307 Failure code [D1B0KY] Hot Short of HST Safety Relay .................................................................. 40-309 WA200-7

00-7

00 Index and foreword Index

Failure code [D1B0MC] Malfunction of HST Safety Relay .............................................................. 40-311 Failure code [D1E6KA] Disconnection of Parking Brake Relay....................................................... 40-312 Failure code [D1E6KB] Ground Fault of Parking Brake Relay ........................................................ 40-314 Failure code [D1E6KY] Hot Short of Parking Brake Relay .............................................................. 40-316 Failure code [D5ZHKA] Failure of Key SW C Signal ....................................................................... 40-318 Failure code [D5ZHKB] Key SW C Signal Hot Short Circuit............................................................ 40-320 Failure code [D5ZHL6] Disconnection of Key SW C ....................................................................... 40-322 Failure code [DAF3KK] Controller Power Source Low (MON) ........................................................ 40-324 Failure code [DAF5KP] 5 V Sensor Power Supply: Ground Fault................................................... 40-326 Failure code [DAF6KP] 24 V Sensor Power Supply: Ground Fault................................................. 40-328 Failure code [DAFRKR] Machine Monitor CAN2 Communication Error (Machine Monitor)............ 40-330 Failure code [DAJ0KK] Controller Power Source Low (HST).......................................................... 40-331 Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST)................................................ 40-334 Failure code [DAJ0MC] HST Controller Malfunction ....................................................................... 40-335 Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) ....................................................... 40-336 Failure code [DAJ2KK] Solenoid Power Source Low (HST) ........................................................... 40-338 Failure code [DAJ4KB] Ground Fault of Solenoid Self-Holding Relay (HST).................................. 40-341 Failure code [DAJ4KZ] Failure of Solenoid Self-Holding Relay (HST) ............................................ 40-343 Failure code [DAJ5KX] Failure of 5 V Power Source 0 (HST)......................................................... 40-345 Failure code [DAJ6KX] Failure of 5 V Power Source 1 (HST)......................................................... 40-347 Failure code [DAJ9KQ] Inconsistency of Model Selection (HST).................................................... 40-349 Failure code [DAJLKA] Operating Lamp Open Circuit (HST).......................................................... 40-350 Failure code [DAJLKB] Operating Lamp Short Circuit (HST) .......................................................... 40-352 Failure code [DAJQKR] CAN2 Disconnection (HST) ...................................................................... 40-354 Failure code [DAJRMA] Inconsistency of Option Selection (HST) .................................................. 40-355 Failure code [DB2QKR] CAN2 Disconnection (Engine Controller).................................................. 40-356 Failure code [DB2RKR] CAN1 Disconnection (Engine Controller).................................................. 40-360 Failure code [DBE6KX] 24V Output Power Supply System Failure ................................................ 40-363 Failure code [DD1NL4] Fan Auto Reverse Switch Signal Error ...................................................... 40-365 Failure code [DD1NLD] Fan Reverse Switch Signal: Abnormal...................................................... 40-367 Failure code [DDB6L4] Parking Brake Signal Malfunction .............................................................. 40-369 Failure code [DDD7KA] Failure of Variable Speed Control ............................................................. 40-371 Failure code [DDD7KY] Hot Short of Variable Speed Control......................................................... 40-373 Failure code [DDE5MA] Disconnection of Steering Oil Pressure Switch (Emergency Steering Control Switch)....................................................................................................................................... 40-375 Failure code [DDK3KA] FNR SW Input Signal Disconnection......................................................... 40-377 Failure code [DDK3KB] FNR SW Input Signal Short Circuit ........................................................... 40-379 Failure code [DDK6KA] FNR Lever Input Signal Disconnection ..................................................... 40-381 Failure code [DDK6KY] FNR Lever Input Signal Disconnection (Hot Short)................................... 40-383 Failure code [DDNRLD] Ground Fault of Work Equipment Lock Switch ......................................... 40-385 Failure code [DDS5L6] Low Steering Oil Pressure (Emergency Steering Control)......................... 40-387 Failure code [DF10KA] Disconnection of Speed Range Input Switch ............................................. 40-389 Failure code [DF10KB] Disconnection of Speed Range Selector Switch (Hot Short) ..................... 40-394 Failure code [DGH1KX] HST Oil Temperature Sensor Short to Ground......................................... 40-399 Failure code [DGR2KB] Ground Fault of Brake Oil Temperature Sensor ....................................... 40-401 Failure code [DGR2KZ] Failure of Brake Oil Temperature Sensor ................................................. 40-403 Failure code [DHH1KX] Failure of HST Oil Pressure Sensor.......................................................... 40-405 Failure code [DHH1KY] Hot Short of HST Oil Pressure Sensor...................................................... 40-407 Failure code [DHPCKX] Failure of Boom Pressure Sensor (Bottom).............................................. 40-409 Failure code [DHPDKX] Failure of Boom Pressure Sensor (Head)................................................. 40-411 Failure code [DHTCL6] HST Oil Filter Clogging Detection Failure.................................................. 40-413 Failure code [DJF1KA] Disconnection or Hot Short Circuit of Fuel Level Sensor ........................... 40-415 Failure code [DK5DKA] Failure of 3rd Lever Potentiometer Sensor (Main) .................................... 40-417 Failure code [DK5DKY] Hot Short of 3rd Lever Potentiometer Sensor (Main) ................................ 40-420 Failure code [DK5DL8] 3rd Lever Potentiometer Sensor (Main & Sub) Disagree........................... 40-422 Failure code [DK5EKA] Failure of 3rd Lever Potentiometer Sensor (Sub)...................................... 40-425 00-8

WA200-7

00 Index and foreword Index

Failure code [DK5EKY] Hot Short of 3rd Lever Potentiometer Sensor (Sub) ................................. 40-428 Failure code [DKA0KX] Failure of Boom Angle Sensor .................................................................. 40-430 Failure code [DLM3KA] Failure of Cooling Fan Speed Sensor ....................................................... 40-432 Failure code [DLM3LC] Ground Fault of Cooling Fan Speed Sensor ............................................. 40-434 Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) .................................................. 40-435 Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) .................................................. 40-437 Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B)........................................................ 40-439 Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ...................................................... 40-442 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indicator .............................................. 40-444 Failure code [DV00KY] Hot Short of Alarm Buzzer ......................................................................... 40-446 Failure code [DW26KA] Open Circuit of Motor 2 Solenoid.............................................................. 40-448 Failure code [DW26KB] Ground Fault of Motor 2 Solenoid............................................................. 40-450 Failure code [DW26KY] Hot Short of Motor 2 Solenoid .................................................................. 40-452 Failure code [DW44KA] Open Circuit of Directional Pressure Selection Solenoid.......................... 40-454 Failure code [DW44KB] Ground Fault of Directional Pressure Selection Solenoid......................... 40-456 Failure code [DW44KY] Hot Short of Directional Pressure Selection Solenoid .............................. 40-458 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid .................................................. 40-460 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid.................................................... 40-462 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ......................................................... 40-464 Failure code [DX19KA] Disconnection of Motor 1 Solenoid ............................................................ 40-466 Failure code [DX19KB] Ground Fault of Motor 1 Solenoid.............................................................. 40-469 Failure code [DX19KY] Hot Short of Motor 1 Solenoid ................................................................... 40-471 Failure code [DX20KA] Disconnection of Clutch EPC Solenoid...................................................... 40-473 Failure code [DX20KB] Ground Fault of Clutch EPC Solenoid ....................................................... 40-476 Failure code [DX20KY] Hot Short of Clutch EPC Solenoid ............................................................. 40-478 Failure code [DXH7KA] Disconnection of Reverse Solenoid .......................................................... 40-480 Failure code [DXH7KB] Ground Fault of Reverse Solenoid............................................................ 40-482 Failure code [DXH7KY] Hot Short of Reverse Solenoid.................................................................. 40-484 Failure code [DXH8KA] Disconnection of Forward Solenoid .......................................................... 40-485 Failure code [DXH8KB] Ground Fault of Forward Solenoid ............................................................ 40-487 Failure code [DXH8KY] Hot Short of Forward Solenoid.................................................................. 40-489 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)................................................ 40-490 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ................................................. 40-492 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ....................................................... 40-494 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ............................................... 40-495 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)................................................. 40-497 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ...................................................... 40-499 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ........................................................ 40-500 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal .................................................... 40-503 Failure code [J141N1] Steering Pump Over Run ............................................................................ 40-505 Failure code [LA00L3] Failure of Fan Reverse................................................................................ 40-506 Failure code [M100N1] HST Pump Over Run ................................................................................. 40-507 Failure code [M400N1] HST Motor 1 Over Run .............................................................................. 40-508 Troubleshooting of electrical system (E-mode)................................................................................... 40-509 E-1 Engine does not start................................................................................................................ 40-509 E-2 Manual preheating system does not work ................................................................................ 40-514 E-3 Automatic preheating system does not work ............................................................................ 40-517 E-4 While preheating is working, preheating monitor does not light up .......................................... 40-519 E-5 When starting switch is turned to ON position, nothing is displayed on machine monitor........ 40-521 E-6 Travel speed is slow ................................................................................................................. 40-524 E-7 ECSS does not operate ............................................................................................................ 40-526 E-8 ECSS remains being operated ................................................................................................. 40-529 E-9 Boom kick-out does not work or is not reset............................................................................. 40-532 E-10 Bucket positioner does not work or is not reset ...................................................................... 40-535 E-11 Boom FLOAT holding does not work or is not reset ............................................................... 40-538 E-12 Directional selection does not work normally.......................................................................... 40-541 WA200-7

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00 Index and foreword Index

E-13 Fan does not rotate in reverse ................................................................................................ 40-552 E-14 Fan remains in reverse rotation mode .................................................................................... 40-555 E-15 Wipers do not operate............................................................................................................. 40-557 E-16 Window washer does not operate........................................................................................... 40-562 E-17 Headlamp, clearance lamp, tail lamp or license-plate lamp does not light up or does not go out .................................................................................................................................................. 40-565 E-18 Working lamp does not light up or does not go out................................................................. 40-574 E-19 Turn signal and hazard lamp do not light up or do not go out................................................. 40-579 E-20 Stop lamp does not light up or remains lighting up ................................................................. 40-586 E-21 Backup lamp does not light up or remains lighting up ............................................................ 40-589 E-22 Backup alarm does not sound or does not stop sounding ...................................................... 40-592 E-23 Horn does not sound or does not stop sounding .................................................................... 40-594 E-24 Alarm buzzer does not sound or does not stop sounding....................................................... 40-597 E-25 KOMTRAX system does not operate normally ....................................................................... 40-599 E-26 Fuel gauge does not indicate correct level ............................................................................. 40-601 E-27 Seat belt caution lamp indication is incorrect.......................................................................... 40-603 Troubleshooting for hydraulic and mechanical system (H-mode) ....................................................... 40-605 Information described in troubleshooting table (H-mode)................................................................ 40-605 System chart of hydraulic and mechanical systems........................................................................ 40-606 Failure mode and cause table ......................................................................................................... 40-608 H-1 Machine travels neither forward nor in reverse......................................................................... 40-614 H-2 Machine does not travel forward (normally travels in reverse) ................................................. 40-616 H-3 Machine does not travel in reverse (normally travels forward) ................................................. 40-617 H-4 Both forward and reverse travel speeds are low ...................................................................... 40-618 H-5 Forward travel speed is low (normal when traveling in reverse)............................................... 40-620 H-6 Reverse travel speed is low (normal when traveling forward) .................................................. 40-621 H-7 Machine lacks power when traveling both forward and in reverse ........................................... 40-622 H-8 Machine lacks power when traveling forward (normal when traveling in reverse).................... 40-624 H-9 Machine lacks power when traveling in reverse (normal when traveling forward).................... 40-625 H-10 Engine stalls during travel or engine speed drops significantly .............................................. 40-626 H-11 Machine does not turn ............................................................................................................ 40-627 H-12 Steering wheel is heavy to turn............................................................................................... 40-629 H-13 Machine sways or large shocks are made while machine turns............................................. 40-630 H-14 Machine turns to either side unintentionally during traveling .................................................. 40-631 H-15 Brake does not work or it is weak ........................................................................................... 40-632 H-16 Brake is not released or drags................................................................................................ 40-633 H-17 Parking brake does not work or it is weak .............................................................................. 40-634 H-18 Parking brake is not released or drags ................................................................................... 40-635 H-19 Boom does not rise................................................................................................................. 40-636 H-20 Boom moves slow or lacks lifting force................................................................................... 40-637 H-21 Boom rising speed lowers at certain height ............................................................................ 40-638 H-22 Lift cylinder cannot hold down bucket (bucket rises off ground) ............................................. 40-639 H-23 Hydraulic drift of boom is large ............................................................................................... 40-640 H-24 Boom wobbles during operation ............................................................................................. 40-644 H-25 Bucket does not tilt back......................................................................................................... 40-645 H-26 Bucket moves slow or lacks tilting back force......................................................................... 40-646 H-27 Bucket speed lowers in tilt-back motion.................................................................................. 40-647 H-28 Bucket cylinder cannot hold down bucket (bucket rises off ground)....................................... 40-648 H-29 Hydraulic drift of bucket is large.............................................................................................. 40-649 H-30 Loaded bucket wobbles during travel (with work equipment valve at "HOLD") ...................... 40-650 H-31 Boom and bucket control levers do not move smoothly and are heavy to move.................... 40-651 H-32 Engine speed lowers remarkably or engine stalls while work equipment is operated ............ 40-652 H-33 Large shock is made when work equipment starts and stops ................................................ 40-653 H-34 When certain work equipment is relieved hydraulically, other work equipment moves .......... 40-654 H-35 ECSS does not operate and machine pitches and bounds .................................................... 40-655 H-36 Fan speed is abnormal (too high or low, or fan does not rotate) ............................................ 40-656 00-10

WA200-7

00 Index and foreword Index

H-37 Unusual noise is heard from around fan................................................................................. 40-658 Troubleshooting of engine (S-mode) .................................................................................................. 40-659 Information mentioned in troubleshooting table (S mode)............................................................... 40-659 S-1 Engine does not crank when starting switch is turned to START position................................ 40-660 S-2 Engine cranks but no exhaust smoke comes out ..................................................................... 40-661 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) . 40-662 S-4 Engine startability is poor.......................................................................................................... 40-663 S-5 Engine does not pick up smoothly ............................................................................................ 40-665 S-6 Engine stops during operation .................................................................................................. 40-667 S-7 Engine runs rough or is unstable .............................................................................................. 40-668 S-8 Engine lacks power................................................................................................................... 40-669 S-9 Exhaust smoke is black ............................................................................................................ 40-671 S-10 Engine oil consumption is excessive ...................................................................................... 40-673 S-11 Oil becomes contaminated quickly ......................................................................................... 40-674 S-12 Fuel consumption is excessive ............................................................................................... 40-675 S-13 Oil is in coolant (or coolant spurts or coolant level goes down).............................................. 40-676 S-14 Oil pressure drops .................................................................................................................. 40-677 S-15 Fuel mixes into engine oil ....................................................................................................... 40-678 S-16 Water mixes into engine oil (milky) ......................................................................................... 40-679 S-17 Coolant temperature rises too high (overheating) .................................................................. 40-680 S-18 Unusual noise is heard ........................................................................................................... 40-681 S-19 Vibration is excessive ............................................................................................................. 40-682 S-20 Air cannot be bled from fuel circuit ......................................................................................... 40-683 50 Disassembly and assembly General information on disassembly and assembly ...............................................................................50-4 How to read this manual......................................................................................................................50-4 Coating materials list ...........................................................................................................................50-6 Special tool list .................................................................................................................................. 50-10 Sketches of special tools................................................................................................................... 50-14 Engine and cooling system ...................................................................................................................50-24 Removal and installation of fuel supply pump assembly................................................................... 50-24 Removal and installation of fuel injector assembly............................................................................ 50-28 Removal and installation of engine hood assembly .......................................................................... 50-36 Removal and installation of cylinder head assembly......................................................................... 50-39 Removal and installation of radiator assembly.................................................................................. 50-51 Removal and installation of air aftercooler assembly ........................................................................ 50-54 Removal and installation of hydraulic oil cooler assembly ................................................................ 50-56 Removal and installation of engine assembly ................................................................................... 50-58 Removal and installation of belt for alternator and air conditioner compressor................................. 50-64 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 ..................................................... 50-74 Removal and installation of fuel tank assembly ................................................................................ 50-77 Removal and installation of KCCV ventilator assembly .................................................................... 50-79 Removal and installation of KDOC muffler........................................................................................ 50-80 Removal and installation of EGR cooler assembly ........................................................................... 50-82 Removal and installation of EGR valve assembly............................................................................. 50-84 Power train............................................................................................................................................50-86 Removal and installation of transfer assembly.................................................................................. 50-86 Disassembly and assembly of transfer assembly ........................................................................... 50-90 Removal and installation of parking brake assembly ...................................................................... 50-113 Removal and installation of parking brake cylinder assembly......................................................... 50-115 Disassembly and assembly of parking brake assembly.................................................................. 50-116 Removal and installation of front axle assembly ............................................................................. 50-122 WA200-7

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00 Index and foreword Index

Removal and installation of rear axle assembly .............................................................................. 50-124 Disassembly and assembly of axle housing assembly.................................................................... 50-127 Disassembly and assembly of differential assembly ....................................................................... 50-136 Undercarriage and frame ....................................................................................................................50-162 Removal and installation of center hinge pin................................................................................... 50-162 Removal and installation of counterweight assembly...................................................................... 50-171 Hydraulic system.................................................................................................................................50-174 Removal and installation of HST pump and quadruple type gear pump assembly ......................... 50-174 Removal and installation of HST motor 1 assembly........................................................................ 50-178 Removal and installation of HST motor 2 assembly........................................................................ 50-180 Removal and installation of work equipment control valve assembly.............................................. 50-183 Removal and installation of ECSS (Electronically Controlled Suspension System) valve assembly .................................................................................................................................................. 50-185 Removal and installation of hydraulic tank assembly ...................................................................... 50-187 Disassembly and assembly of hydraulic cylinder assembly ............................................................ 50-189 Work equipment ..................................................................................................................................50-193 Removal and installation of work equipment assembly................................................................... 50-193 Cab and its attachments .....................................................................................................................50-199 Removal and installation of operator's cab and floor frame assembly ............................................ 50-199 Removal and installation of operator's cab glass (adhered glass) .................................................. 50-204 Disassembly and assembly of operator's seat ................................................................................ 50-212 Removal and installation of air conditioner unit assembly............................................................... 50-222 Removal and installation of air conditioner compressor assembly.................................................. 50-228 Electrical system .................................................................................................................................50-230 Removal and installation of machine monitor.................................................................................. 50-230 Removal and installation of engine controller assembly.................................................................. 50-232 Removal and installation of HST controller assembly ..................................................................... 50-234 Removal and installation of KOMTRAX terminal assembly............................................................. 50-235 60 Maintenance standard Engine and cooling system .................................................................................................................... 60-3 Engine mount and transfer mount ...................................................................................................... 60-3 Damper............................................................................................................................................... 60-4 Cooling system ................................................................................................................................... 60-5 Cooling fan motor ............................................................................................................................... 60-6 Power train ............................................................................................................................................. 60-8 Drive shaft .......................................................................................................................................... 60-8 Transfer ........................................................................................................................................... 60-9 Axle.................................................................................................................................................. 60-17 Differential ....................................................................................................................................... 60-19 Limited slip differential ..................................................................................................................... 60-23 Final drive ........................................................................................................................................ 60-25 Steering system .................................................................................................................................. 60-28 Orbitrol valve ................................................................................................................................... 60-28 Steering cylinder.............................................................................................................................. 60-29 Steering column............................................................................................................................... 60-32 Priority valve .................................................................................................................................... 60-33 Emergency steering valve ............................................................................................................... 60-34 Brake system ...................................................................................................................................... 60-36 Charge valve ................................................................................................................................... 60-36 Slack adjuster .................................................................................................................................. 60-38 Brake ............................................................................................................................................... 60-39 Parking brake .................................................................................................................................. 60-41 Undercarriage and frame .................................................................................................................... 60-42 Axle mount and center hinge pin ..................................................................................................... 60-42 00-12

WA200-7

00 Index and foreword Index

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.................................................................................................................

60-46 60-46 60-47 60-53 60-56 60-57 60-59 60-59 60-61 60-62 60-63

80 Appendix Air conditioner .........................................................................................................................................80-3 Precautions for refrigerant...................................................................................................................80-3 Air conditioner component...................................................................................................................80-4 Configuration and function of refrigeration cycle .................................................................................80-6 Outline of refrigeration cycle................................................................................................................80-7 Air conditioner unit...............................................................................................................................80-9 Functions of main components in air conditioner unit ....................................................................... 80-10 Blower and intake unit ....................................................................................................................... 80-11 Compressor....................................................................................................................................... 80-12 Condenser......................................................................................................................................... 80-13 Receiver drier .................................................................................................................................... 80-14 Air conditioner control panel.............................................................................................................. 80-15 Procedure for troubleshooting ........................................................................................................... 80-16 Circuit diagram and arrangement of connector pins ......................................................................... 80-18 System diagram ................................................................................................................................ 80-20 Details of air conditioner unit ............................................................................................................. 80-22 Parts and connectors layout.............................................................................................................. 80-23 Inspection by self-diagnosis function (displays diagnosis on the control panel) ............................... 80-25 Testing temperature control system .................................................................................................. 80-26 Testing FRESH/RECIRC air changeover.......................................................................................... 80-27 Testing evaporator temperature sensor ............................................................................................ 80-29 Testing relays .................................................................................................................................... 80-30 Troubleshooting chart 1..................................................................................................................... 80-31 Troubleshooting chart 2..................................................................................................................... 80-33 Information described in troubleshooting table.................................................................................. 80-36 Troubleshooting for power supply system (Air conditioner does not operate) .................................. 80-37 Troubleshooting for compressor and refrigerant system (Air is not cooled)...................................... 80-41 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...................... 80-44 Troubleshooting for temperature control ........................................................................................... 80-47 Troubleshooting for FRESH/RECIRC air changeover....................................................................... 80-50 Connection of service tool ................................................................................................................. 80-52 Troubleshooting by gauge pressure.................................................................................................. 80-54 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit................. 80-57 Handling of compressor oil................................................................................................................ 80-59 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 WA200-7

00-13