WA200-7 | SN: 80001-UP and more | Komatsu | Heavy Equipment Manual PDF

WHEELLOADER

MachinemodelSerialnumber

WA200-780001andup

00Indexandforeword

Indexandforeword Index

00Indexandforeword

Indexandforeword.................................................................................................................................00-2

Foreword,safetyandgeneralinformation.............................................................................................00-14

Importantsafetynotice......................................................................................................................00-14

Howtoreadtheshopmanual............................................................................................................00-21

Explanationoftermsformaintenancestandard................................................................................00-23

Handlingequipmentoffuelsystemdevices......................................................................................00-25

Handlingofintakesystemparts........................................................................................................00-26

Handlingofhydraulicequipment.......................................................................................................00-27

Methodofdisconnectingandconnectingofpush-pulltypecoupler..................................................00-29

Handlingofelectricalequipment.......................................................................................................00-32

Howtoreadelectricwirecode..........................................................................................................00-40

Precautionswhenperformingoperation............................................................................................00-43

PracticaluseofKOMTRAX...............................................................................................................00-48

Standardtighteningtorquetable.......................................................................................................00-49

ListofAbbreviation............................................................................................................................00-55 Conversiontable................................................................................................................................00-59

01Specifications

Specifications..........................................................................................................................................01-4

Specificationdimensiondrawing.........................................................................................................01-4

Specifications......................................................................................................................................01-6

Weighttable.......................................................................................................................................01-14

Tableoffuel,coolant,andlubricants.................................................................................................01-18

10Structureandfunction

Engineandcoolingsystem.....................................................................................................................10-4

VFT......................................................................................................................................................10-4

EGRsystempipingdrawing................................................................................................................10-8

EGRsystemcircuitdiagram..............................................................................................................10-10

EGRvalve.........................................................................................................................................10-12

EGRcooler........................................................................................................................................10-14

KCCVlayoutdrawing........................................................................................................................10-16

KCCVventilator.................................................................................................................................10-19

KDOCmuffler....................................................................................................................................10-23

Damper..............................................................................................................................................10-25

Coolingsystem..................................................................................................................................10-26

Coolingsystemhydraulicpipingdiagram..........................................................................................10-27

Coolingfanmotor..............................................................................................................................10-28

Powertrain............................................................................................................................................10-37

Powertrain........................................................................................................................................10-37

Powertrainsystemdiagram..............................................................................................................10-38 Driveshaft.........................................................................................................................................10-40

HSThydraulicpipingdiagram...........................................................................................................10-41 HSTpump.........................................................................................................................................10-42

HSTmotor.........................................................................................................................................10-50

Transfer.............................................................................................................................................10-56

Clutchsolenoidvalve.........................................................................................................................10-62

Axle....................................................................................................................................................10-63

Differential.........................................................................................................................................10-65

Torqueproportioningdifferential........................................................................................................10-68

Limitedslipdifferential.......................................................................................................................10-69

Finaldrive..........................................................................................................................................10-72

Steeringsystem....................................................................................................................................10-75

Steeringpipingdiagram....................................................................................................................10-75 Orbitrolvalve.....................................................................................................................................10-76

Steeringcolumn................................................................................................................................10-84

Priorityvalve......................................................................................................................................10-85

Emergencysteeringvalve.................................................................................................................10-88

Brakesystem........................................................................................................................................10-91

Brakepipingdiagram........................................................................................................................10-91

Brakevalve........................................................................................................................................10-92

Chargevalve.....................................................................................................................................10-96

Accumulator(forbrake)...................................................................................................................10-100

Slackadjuster..................................................................................................................................10-101

Brake...............................................................................................................................................10-103

Parkingbrakecontrol......................................................................................................................10-106

Parkingbrake..................................................................................................................................10-107

Parkingbrakecylinder.....................................................................................................................10-108

Parkingbrakesolenoidvalve..........................................................................................................10-109

Inchingvalve...................................................................................................................................10-111

Undercarriageandframe....................................................................................................................10-112

Axlemountandcenterhingepin.....................................................................................................10-112

Hydraulicsystem.................................................................................................................................10-114

Hydrauliccomponentlayout............................................................................................................10-114

Workequipmentcontrolleverlinkage.............................................................................................10-116

Hydraulictank..................................................................................................................................10-117

Accumulator(forPPCcircuit)..........................................................................................................10-119

Workequipmentcontrolvalve.........................................................................................................10-120

PPCvalve........................................................................................................................................10-133

AttachmentEPCvalve....................................................................................................................10-139

Workequipmentlocksolenoidvalve...............................................................................................10-140

ECSSvalve.....................................................................................................................................10-141

Accumulator(forECSS)..................................................................................................................10-143

2-wayrestrictorvalve......................................................................................................................10-144

Cushionvalve..................................................................................................................................10-145

Accumulator(foroilcoolercircuit)...................................................................................................10-146

Quadruplegearpump.....................................................................................................................10-147

Quickcouplersolenoidvalve...........................................................................................................10-148

Workequipment..................................................................................................................................10-149

Workequipmentlinkage..................................................................................................................10-149

Bucket.............................................................................................................................................10-151

Bucketpositionerandboomkick-out..............................................................................................10-152

Cabanditsattachments.....................................................................................................................10-158

Cab..................................................................................................................................................10-158

Electricalsystem.................................................................................................................................10-159

Machinemonitorsystem.................................................................................................................10-159

Machinemonitor..............................................................................................................................10-164

Electricalsystem(HSTcontrollersystem).......................................................................................10-186 Systemcomponentparts.................................................................................................................10-202 HSTcontroller.................................................................................................................................10-208

ECSS...............................................................................................................................................10-212

KOMTRAXsystem..........................................................................................................................10-214

Enginestartingcircuit......................................................................................................................10-217

Enginestoppingcircuit....................................................................................................................10-219

Preheatingsystem...........................................................................................................................10-220

Automaticpreheatingsystem..........................................................................................................10-221

Manualpreheatingsystem..............................................................................................................10-221

Engineoutputlimitfunction.............................................................................................................10-222

Automaticwarm-upfunction............................................................................................................10-222

Parkingbrakecontrolsystem..........................................................................................................10-223

Multi-functionmono-lever................................................................................................................10-227 Sensor.............................................................................................................................................10-229

20Standardvaluetable

Standardvaluetable...............................................................................................................................20-3

Standardvaluetableforengine...........................................................................................................20-3 Standardvaluetableformachine........................................................................................................20-5

30Testingandadjusting

Relatedinformationontestingandadjusting..........................................................................................30-4

Toolsfortestingandadjusting.............................................................................................................30-4

Engineandcoolingsystem.....................................................................................................................30-7

Testingandadjustingenginespeed....................................................................................................30-7

Testingexhaustgastemperature........................................................................................................30-9

Testingexhaustgascolor.................................................................................................................30-10

Testingandadjustingvalveclearance.............................................................................................30-12

Testingcompressionpressure.........................................................................................................30-14

Testingblowbypressure...................................................................................................................30-17

Testingengineoilpressure..............................................................................................................30-18

Testingboostpressure.....................................................................................................................30-19

Handlingequipmentoffuelsystemdevices.....................................................................................30-21

Releasingremainingpressurefromfuelsystem..............................................................................30-21

VisualcheckinsideofEGRvalve..................................................................................................30-21-1

CleaninsideofEGRvalve.............................................................................................................30-21-2

Testingfuelpressure........................................................................................................................30-22

Testingfueldischarge,returnandleakage......................................................................................30-27

Bleedingairfromfuelsystem...........................................................................................................30-32

Testingfuelcircuitforleakage..........................................................................................................30-34

Handlingcylindercutoutmodeoperation.........................................................................................30-35

Handlingno-injectioncrankingoperation.........................................................................................30-35

TestingKDPFandmufflerstackforloosenessanddamage...........................................................30-36

TestingKDOCfunction.....................................................................................................................30-36

Testinginstalledconditionofcylinderheadsandmanifolds.............................................................30-37

Testingenginepipingfordamageandlooseness............................................................................30-37

Testingandadjustingairconditionercompressorbelttension.........................................................30-38

Testingandreplacingalternatorbelt................................................................................................30-39

Testingandreplacingauto-tensioner...............................................................................................30-41

Powertrain............................................................................................................................................30-43

Testingoilleakagefromaxlefinaldrive...........................................................................................30-43

Testingdriveshaftforlooseness,backlash,anddamage................................................................30-44

Testingacceleratorpedal.................................................................................................................30-45

TestingandadjustingHSToilpressure............................................................................................30-47

Testingtransferclutchcontrolpressure...........................................................................................30-52

Steeringsystem....................................................................................................................................30-53

Testingdirectionallever....................................................................................................................30-53

Testingandadjustingsteeringwheel...............................................................................................30-54

Testingworkequipmentcontrollever...............................................................................................30-56

Testingandadjustingsteeringcircuitoilpressure............................................................................30-57

Bleedingairfromsteeringcircuit......................................................................................................30-59

Brakesystem.......................................................................................................................................30-60

00-4WA200-7

Testingbrakepedal..........................................................................................................................30-60

Testingandadjustingbrakepedalandlinkage................................................................................30-61

Testingbrakingperformance............................................................................................................30-62

Testingandadjustingaccumulatorchargepressure........................................................................30-63

Testingwheelbrakeoilpressure......................................................................................................30-65

Testingloweringofwheelbrakepressure........................................................................................30-66

Testingwearofwheelbrakedisc.....................................................................................................30-69

Bleedingairfromwheelbrakecircuit...............................................................................................30-70

Releasingremainingpressureinbrakeaccumulatorcircuit.............................................................30-71

Testingparkingbrakeperformance..................................................................................................30-72

Testingparkingbrakereleasepressure...........................................................................................30-73

Methodofreleasingparkingbrakemanually....................................................................................30-74

Hydraulicsystem...................................................................................................................................30-75

Testingandadjustingcoolingfanspeed..........................................................................................30-75

Testingcoolingfanpumpcircuitoilpressure....................................................................................30-76

TestingworkequipmentPPCoilpressure........................................................................................30-77

Testingandadjustingworkequipmentoilpressure..........................................................................30-78

Bleedingairfromeachpart...............................................................................................................30-79

Releasingremainingpressureinhydrauliccircuit.............................................................................30-80

Workequipment....................................................................................................................................30-81

Testingandadjustingbucketpositioner............................................................................................30-81

Testingandadjustingboomkick-outswitch......................................................................................30-82

Checkingtheproximityswitchworkingpilotlamp.............................................................................30-83

Electricalsystem...................................................................................................................................30-85

Adjustingreplaced,reassembledoraddedsensor,controller,etc.withmachinemonitor................30-85

Specialfunctionsofmachinemonitor................................................................................................30-87

KOMTRAXterminalstart-upprocedure..........................................................................................30-141

LampindicationofKOMTRAXterminal...........................................................................................30-144

Handlingvoltagecircuitofcontroller...............................................................................................30-148

Testdiodes......................................................................................................................................30-149 PmClinic.............................................................................................................................................30-150 PmClinicservice.............................................................................................................................30-150

40Troubleshooting

Relatedinformationontroubleshooting..................................................................................................40-9

Pointstorememberwhenperformingtroubleshooting........................................................................40-9

Howtoproceedintroubleshooting....................................................................................................40-11

Checksbeforetroubleshooting..........................................................................................................40-13

Checkprocedurebeforetroubleshooting..........................................................................................40-15

Preparationfortroubleshootingofelectricalsystem.........................................................................40-33

Classificationandproceduresoftroubleshooting..............................................................................40-38

SymptomandtroubleshootingNo.....................................................................................................40-42

Informationdescribedintroubleshootingtable..................................................................................40-44

Procedurefortroubleshootingofopencircuitinwiringharnessofpressuresensorsystem............40-46

Connectorlistandlayout...................................................................................................................40-48

ConnectiontableofconnectorbyNo.ofpins....................................................................................40-61

T-boxandT-adapterlist....................................................................................................................40-98

Fuselocationtable..........................................................................................................................40-102

Failurecodelist...............................................................................................................................40-105

Troubleshootingbyfailurecode(Displayofcode)..............................................................................40-113

Failurecode[2F00MB]MalfunctionofParkingBrake.....................................................................40-113

Failurecode[2G42ZG]AccumulatorOilPressureLow(Front).......................................................40-115

Failurecode[2G43ZG]AccumulatorOilPressureLow(Rear).......................................................40-117

Failurecode[6091NX]HSTFilterClogging....................................................................................40-119

Failurecode[7RHYKA]OpenCircuitofFanMotorEPCSolenoidOutput......................................40-121

WA200-700-5

Failurecode[7RHYKB]GroundFaultofFanMotorEPCSolenoidOutput.....................................40-123 Failurecode[7RHYKY]HotShortofFanMotorEPCSolenoidOutput...........................................40-125 Failurecode[989FN1]TravelSpeedOverrunAlarm......................................................................40-127 Failurecode[AB00L6]DischargeofAlternatorRTerminal.............................................................40-128 Failurecode[AB00MA]GroundFaultorOpenCircuitofBatteryRelayStatusSignalLine,orInsufficient BatteryCharging.......................................................................................................................40-130 Failurecode[B@BAZG]EngineOilPressureLow.........................................................................40-132 Failurecode[B@BCNS]EngineWaterOverheat...........................................................................40-133 Failurecode[B@BCZK]EngineCoolantLevelLow.......................................................................40-134 Failurecode[B@C6NS]FrontBrakeOilTemperatureOverheat(ThisAlarm)...............................40-136 Failurecode[B@CRNS]HSTOilTemperatureOverheat...............................................................40-137 Failurecode[CA115]EngNeandBkupSpeedSensError............................................................40-138 Failurecode[CA122]ChargeAirPressureSensorHighError.......................................................40-139 Failurecode[CA123]ChargeAirPressureSensorLowError........................................................40-141 Failurecode[CA131]ThrottleSensorHighError............................................................................40-143 Failurecode[CA132]ThrottleSensorLowError.............................................................................40-145 Failurecode[CA144]CoolantTemperatureSensorHighError......................................................40-147 Failurecode[CA145]CoolantTemperatureSensorLowError.......................................................40-149 Failurecode[CA153]ChargeAirTemperatureSensorHighError.................................................40-151 Failurecode[CA154]ChgAirTempSensorLowError...................................................................40-153 Failurecode[CA187]Sensor2SupplyVoltageLowError..............................................................40-155 Failurecode[CA221]AmbientPressureSensorHighError...........................................................40-157 Failurecode[CA222]AmbientPressureSensorLowError............................................................40-159 Failurecode[CA227]Sensor2SupplyVoltageHighError.............................................................40-161 Failurecode[CA234]EngineOverspeed........................................................................................40-162 Failurecode[CA238]NeSpeedSensorSupplyVoltError.............................................................40-163 Failurecode[CA239]NeSpeedSensSupplyVoltHighError........................................................40-164 Failurecode[CA271]IMV/PCV1ShortError..................................................................................40-165 Failurecode[CA272]IMV/PCV1OpenError..................................................................................40-167 Failurecode[CA295]AmbientPressSensInRangeError.............................................................40-169 Failurecode[CA322]Injector#1(L#1)Open/ShortError...............................................................40-170 Failurecode[CA324]Injector#3(L#3)Open/ShortError...............................................................40-172 Failurecode[CA331]Injector#2(L#2)Open/ShortError...............................................................40-174 Failurecode[CA332]Injector#4(L#4)Open/ShortError...............................................................40-176 Failurecode[CA343]EngineControllerInternalFailure.................................................................40-178 Failurecode[CA351]InjectorsDriveCircuitError...........................................................................40-179 Failurecode[CA352]Sensor1SupplyVoltageLowError..............................................................40-180 Failurecode[CA356]MassAirFlowSensorHighError.................................................................40-182 Failurecode[CA357]MassAirFlowSensorLowError..................................................................40-184 Failurecode[CA386]Sensor1SupplyVoltageHighError.............................................................40-186 Failurecode[CA428]WaterinFuelSensorHighError...................................................................40-187 Failurecode[CA429]WaterinFuelSensorLowError...................................................................40-189 Failurecode[CA431]IdleValidationSwError................................................................................40-191 Failurecode[CA432]IdleValidationProcessError........................................................................40-194 Failurecode[CA435]EngineOilPressureSwError.......................................................................40-196 Failurecode[CA441]BatteryVoltageLowError.............................................................................40-197 Failurecode[CA442]BatteryVoltageHighError............................................................................40-199 Failurecode[CA449]RailPressVeryHighError............................................................................40-200 Failurecode[CA451]CommonRailPressureSensorHighError...................................................40-201 Failurecode[CA452]CommonRailPressureSensorLowError....................................................40-203 Failurecode[CA466]KVGTMotorDriverPositionError................................................................40-205 Failurecode[CA488]ChgAirTempHighTorqueDerate...............................................................40-207 Failurecode[CA515]RailPressureSensorSupVoltHighError....................................................40-208 Failurecode[CA516]RailPressureSensorSupVoltLowError.....................................................40-210 Failurecode[CA553]CommonRailPressureHighError1............................................................40-212 Failurecode[CA555]CrankcasePressHighError1......................................................................40-213

Failurecode[CA556]CrankcasePressHighError2......................................................................40-214

Failurecode[CA559]RailPressLowError1..................................................................................40-215

Failurecode[CA689]EngineNeSpeedSensorError....................................................................40-218

Failurecode[CA691]IntakeAirTempSensHighError..................................................................40-220

Failurecode[CA692]IntakeAirTempSensLowError..................................................................40-222

Failurecode[CA697]ECMInternalTemperatureSensorHighError.............................................40-224

Failurecode[CA698]EMCInternalTemperatureSensorLowError..............................................40-225

Failurecode[CA731]EngineBkupSpeedSensorPhaseError.....................................................40-226

Failurecode[CA778]EngineBkupSpeedSensorError................................................................40-228

Failurecode[CA1117]PersistentDataLostError..........................................................................40-233

Failurecode[CA1695]Sensor5SupplyVoltageHighError...........................................................40-234

Failurecode[CA1696]Sensor5SupplyVoltageLowError...........................................................40-235

Failurecode[CA1843]CrankcasePressSensHighError..............................................................40-236

Failurecode[CA1844]CrankcasePressSensLowError..............................................................40-238

Failurecode[CA1896]EGRValveStuckError...............................................................................40-240 Failurecode[CA1942]CrankcasePressSensIn-RangeError......................................................40-241 Failurecode[CA1961]EGRMotorDriverICOverTempError......................................................40-242 Failurecode[CA2185]ThrottleSensorSupplyVoltageHighError................................................40-243 Failurecode[CA2186]ThrottleSensorSupplyVoltageLowError.................................................40-245 Failurecode[CA2249]RailPressLowError2................................................................................40-247 Failurecode[CA2272]EGRValvePositionSensorLowError.......................................................40-248 Failurecode[CA2311]IMVSolenoidError.....................................................................................40-250 Failurecode[CA2349]EGRValveSolenoidOpenCircuitError.....................................................40-251 Failurecode[CA2353]EGRValveSolenoidShortCircuitError.....................................................40-253 Failurecode[CA2357]EGRValveServoError..............................................................................40-255 Failurecode[CA2373]ExhaustManifoldPressureSensorHighError...........................................40-256 Failurecode[CA2374]ExhaustManifoldPressureSensorLowError............................................40-258 Failurecode[CA2375]EGROrificeTemperatureSensorHighError.............................................40-260 Failurecode[CA2376]EGROrificeTemperatureSensorLowError..............................................40-262 Failurecode[CA2554]ExhaustManifoldPressureSensorIn-RangeError...................................40-264 Failurecode[CA2555]GridHeaterRelayVoltageLowError.........................................................40-265 Failurecode[CA2556]GridHeaterRelayVoltageHighError........................................................40-267 Failurecode[CA2961]EGROrificeTemperatureHighError1......................................................40-269 Failurecode[CA2973]ChargeAirPressureSensorIn-RangeError..............................................40-270 Failurecode[CA3419]MassAirFlowSensorSupVoltHighError.................................................40-271 Failurecode[CA3421]MassAirFlowSensorSupVoltLowError.................................................40-273 Failurecode[CA3724]EGR/KVGTMotorDriverPowerLowError................................................40-275 Failurecode[CA3741]CommonRailPressureValveTripError....................................................40-277 Failurecode[CA3918]KVGTStuckError.......................................................................................40-278 Failurecode[CA3919]KVGTMotorDriverICOverTemperatureError.........................................40-279 Failurecode[CA3921]KVGTServoError2...................................................................................40-280 Failurecode[CA3922]KVGTMotorDriverOpenError..................................................................40-281 Failurecode[CA3923]KVGTMotorDriverShortError..................................................................40-283 Failurecode[D110L4]DisconnectionorShorttoGroundofBatteryRelaySignalLine.................40-285 Failurecode[D160KA]DisconnectionofBackupLampRelayOutput............................................40-287 Failurecode[D160KB]GroundFaultofBackupLampRelayOutput.............................................40-289 Failurecode[D160KY]HotShortofBackupLampRelayOutput...................................................40-291 Failurecode[D191KA]DisconnectionofNeutralOutputRelay......................................................40-293 Failurecode[D191KB]GroundFaultofNeutralOutputRelay........................................................40-295 Failurecode[D191KY]HotShortofNeutralOutputRelay.............................................................40-297 Failurecode[D192KA]DisconnectionofECSSSolenoidRelay.....................................................40-299 Failurecode[D192KB]GroundFaultofECSSSolenoidRelay......................................................40-301 Failurecode[D192KY]HotShortofECSSSolenoidRelay............................................................40-303 Failurecode[D1B0KA]DisconnectionofHSTSafetyRelay...........................................................40-305 Failurecode[D1B0KB]GroundFaultofHSTSafetyRelay............................................................40-307 Failurecode[D1B0KY]HotShortofHSTSafetyRelay..................................................................40-309

Failurecode[D1B0MC]MalfunctionofHSTSafetyRelay..............................................................40-311 Failurecode[D1E6KA]DisconnectionofParkingBrakeRelay.......................................................40-312 Failurecode[D1E6KB]GroundFaultofParkingBrakeRelay........................................................40-314 Failurecode[D1E6KY]HotShortofParkingBrakeRelay..............................................................40-316 Failurecode[D5ZHKA]FailureofKeySWCSignal.......................................................................40-318 Failurecode[D5ZHKB]KeySWCSignalHotShortCircuit............................................................40-320 Failurecode[D5ZHL6]DisconnectionofKeySWC.......................................................................40-322 Failurecode[DAF3KK]ControllerPowerSourceLow(MON)........................................................40-324 Failurecode[DAF5KP]5VSensorPowerSupply:GroundFault...................................................40-326 Failurecode[DAF6KP]24VSensorPowerSupply:GroundFault.................................................40-328 Failurecode[DAFRKR]MachineMonitorCAN2CommunicationError(MachineMonitor)............40-330 Failurecode[DAJ0KK]ControllerPowerSourceLow(HST)..........................................................40-331 Failurecode[DAJ0KT]AbnormalityofNon-volatileMemory(HST)................................................40-334 Failurecode[DAJ0MC]HSTControllerMalfunction.......................................................................40-335 Failurecode[DAJ1KA]DisconnectionofKeySWACC(HST).......................................................40-336 Failurecode[DAJ2KK]SolenoidPowerSourceLow(HST)...........................................................40-338 Failurecode[DAJ4KB]GroundFaultofSolenoidSelf-HoldingRelay(HST)..................................40-341 Failurecode[DAJ4KZ]FailureofSolenoidSelf-HoldingRelay(HST)............................................40-343 Failurecode[DAJ5KX]Failureof5VPowerSource0(HST).........................................................40-345 Failurecode[DAJ6KX]Failureof5VPowerSource1(HST).........................................................40-347 Failurecode[DAJ9KQ]InconsistencyofModelSelection(HST)....................................................40-349 Failurecode[DAJLKA]OperatingLampOpenCircuit(HST)..........................................................40-350 Failurecode[DAJLKB]OperatingLampShortCircuit(HST)..........................................................40-352 Failurecode[DAJQKR]CAN2Disconnection(HST)......................................................................40-354 Failurecode[DAJRMA]InconsistencyofOptionSelection(HST)..................................................40-355 Failurecode[DB2QKR]CAN2Disconnection(EngineController)..................................................40-356 Failurecode[DB2RKR]CAN1Disconnection(EngineController)..................................................40-360 Failurecode[DBE6KX]24VOutputPowerSupplySystemFailure................................................40-363 Failurecode[DD1NL4]FanAutoReverseSwitchSignalError......................................................40-365 Failurecode[DD1NLD]FanReverseSwitchSignal:Abnormal......................................................40-367 Failurecode[DDB6L4]ParkingBrakeSignalMalfunction..............................................................40-369 Failurecode[DDD7KA]FailureofVariableSpeedControl.............................................................40-371 Failurecode[DDD7KY]HotShortofVariableSpeedControl.........................................................40-373 Failurecode[DDE5MA]DisconnectionofSteeringOilPressureSwitch(EmergencySteeringControl Switch).......................................................................................................................................40-375 Failurecode[DDK3KA]FNRSWInputSignalDisconnection.........................................................40-377 Failurecode[DDK3KB]FNRSWInputSignalShortCircuit...........................................................40-379 Failurecode[DDK6KA]FNRLeverInputSignalDisconnection.....................................................40-381 Failurecode[DDK6KY]FNRLeverInputSignalDisconnection(HotShort)...................................40-383 Failurecode[DDNRLD]GroundFaultofWorkEquipmentLockSwitch.........................................40-385 Failurecode[DDS5L6]LowSteeringOilPressure(EmergencySteeringControl).........................40-387 Failurecode[DF10KA]DisconnectionofSpeedRangeInputSwitch.............................................40-389 Failurecode[DF10KB]DisconnectionofSpeedRangeSelectorSwitch(HotShort).....................40-394 Failurecode[DGH1KX]HSTOilTemperatureSensorShorttoGround.........................................40-399 Failurecode[DGR2KB]GroundFaultofBrakeOilTemperatureSensor.......................................40-401 Failurecode[DGR2KZ]FailureofBrakeOilTemperatureSensor.................................................40-403 Failurecode[DHH1KX]FailureofHSTOilPressureSensor..........................................................40-405 Failurecode[DHH1KY]HotShortofHSTOilPressureSensor......................................................40-407 Failurecode[DHPCKX]FailureofBoomPressureSensor(Bottom)..............................................40-409 Failurecode[DHPDKX]FailureofBoomPressureSensor(Head).................................................40-411 Failurecode[DHTCL6]HSTOilFilterCloggingDetectionFailure..................................................40-413 Failurecode[DJF1KA]DisconnectionorHotShortCircuitofFuelLevelSensor...........................40-415 Failurecode[DK5DKA]Failureof3rdLeverPotentiometerSensor(Main)....................................40-417 Failurecode[DK5DKY]HotShortof3rdLeverPotentiometerSensor(Main)................................40-420 Failurecode[DK5DL8]3rdLeverPotentiometerSensor(Main&Sub)Disagree...........................40-422 Failurecode[DK5EKA]Failureof3rdLeverPotentiometerSensor(Sub)......................................40-425

00-8WA200-7

Failurecode[DK5EKY]HotShortof3rdLeverPotentiometerSensor(Sub).................................40-428 Failurecode[DKA0KX]FailureofBoomAngleSensor..................................................................40-430 Failurecode[DLM3KA]FailureofCoolingFanSpeedSensor.......................................................40-432 Failurecode[DLM3LC]GroundFaultofCoolingFanSpeedSensor.............................................40-434 Failurecode[DLT3KX]VehicleSpeedSensorCircuitFailure(B)..................................................40-435 Failurecode[DLT4KX]VehicleSpeedSensorCircuitFailure(A)..................................................40-437 Failurecode[DLT4L0]VehicleSpeedSensorFailure(A&B)........................................................40-439 Failurecode[DLT4LC]VehicleSpeedSensorFailure(AorB)......................................................40-442 Failurecode[DT22KB]GroundFaultofWorkEquip.LockIndicator..............................................40-444 Failurecode[DV00KY]HotShortofAlarmBuzzer.........................................................................40-446 Failurecode[DW26KA]OpenCircuitofMotor2Solenoid..............................................................40-448 Failurecode[DW26KB]GroundFaultofMotor2Solenoid.............................................................40-450 Failurecode[DW26KY]HotShortofMotor2Solenoid..................................................................40-452 Failurecode[DW44KA]OpenCircuitofDirectionalPressureSelectionSolenoid..........................40-454 Failurecode[DW44KB]GroundFaultofDirectionalPressureSelectionSolenoid.........................40-456 Failurecode[DW44KY]HotShortofDirectionalPressureSelectionSolenoid..............................40-458 Failurecode[DWM1KA]DisconnectionofNeutralLockSolenoid..................................................40-460 Failurecode[DWM1KB]GroundFaultofNeutralLockSolenoid....................................................40-462 Failurecode[DWM1KY]HotShortofNeutralLockSolenoid.........................................................40-464 Failurecode[DX19KA]DisconnectionofMotor1Solenoid............................................................40-466 Failurecode[DX19KB]GroundFaultofMotor1Solenoid..............................................................40-469 Failurecode[DX19KY]HotShortofMotor1Solenoid...................................................................40-471 Failurecode[DX20KA]DisconnectionofClutchEPCSolenoid......................................................40-473 Failurecode[DX20KB]GroundFaultofClutchEPCSolenoid.......................................................40-476 Failurecode[DX20KY]HotShortofClutchEPCSolenoid.............................................................40-478 Failurecode[DXH7KA]DisconnectionofReverseSolenoid..........................................................40-480 Failurecode[DXH7KB]GroundFaultofReverseSolenoid............................................................40-482 Failurecode[DXH7KY]HotShortofReverseSolenoid..................................................................40-484 Failurecode[DXH8KA]DisconnectionofForwardSolenoid..........................................................40-485 Failurecode[DXH8KB]GroundFaultofForwardSolenoid............................................................40-487 Failurecode[DXH8KY]HotShortofForwardSolenoid..................................................................40-489 Failurecode[DXHJKA]Disconnectionof3rdEPCSolenoid(EXT)................................................40-490 Failurecode[DXHJKB]GroundFaultof3rdEPCSolenoid(EXT).................................................40-492 Failurecode[DXHJKY]HotShortof3rdEPCSolenoid(EXT).......................................................40-494 Failurecode[DXHKKA]Disconnectionof3rdEPCSolenoid(RET)...............................................40-495 Failurecode[DXHKKB]GroundFaultof3rdEPCSolenoid(RET).................................................40-497 Failurecode[DXHKKY]HotShortof3rdEPCSolenoid(RET)......................................................40-499 Failurecode[H2K0KA]FailureofQuickCouplerLockSignal........................................................40-500 Failurecode[H2K0KY]HotShortofQuickCouplerLockSignal....................................................40-503 Failurecode[J141N1]SteeringPumpOverRun............................................................................40-505 Failurecode[LA00L3]FailureofFanReverse................................................................................40-506 Failurecode[M100N1]HSTPumpOverRun.................................................................................40-507 Failurecode[M400N1]HSTMotor1OverRun..............................................................................40-508 Troubleshootingofelectricalsystem(E-mode)...................................................................................40-509 E-1Enginedoesnotstart................................................................................................................40-509

E-2Manualpreheatingsystemdoesnotwork................................................................................40-514

E-3Automaticpreheatingsystemdoesnotwork............................................................................40-517

E-4Whilepreheatingisworking,preheatingmonitordoesnotlightup..........................................40-519

E-5WhenstartingswitchisturnedtoONposition,nothingisdisplayedonmachinemonitor........40-521

E-6Travelspeedisslow.................................................................................................................40-524

E-7ECSSdoesnotoperate............................................................................................................40-526

E-8ECSSremainsbeingoperated.................................................................................................40-529

E-9Boomkick-outdoesnotworkorisnotreset.............................................................................40-532

E-10Bucketpositionerdoesnotworkorisnotreset......................................................................40-535

E-11BoomFLOATholdingdoesnotworkorisnotreset...............................................................40-538

E-12Directionalselectiondoesnotworknormally..........................................................................40-541

E-13Fandoesnotrotateinreverse................................................................................................40-552

E-14Fanremainsinreverserotationmode....................................................................................40-555

E-15Wipersdonotoperate.............................................................................................................40-557

E-16Windowwasherdoesnotoperate...........................................................................................40-562

E-17Headlamp,clearancelamp,taillamporlicense-platelampdoesnotlightupordoesnotgoout ..................................................................................................................................................40-565

E-18Workinglampdoesnotlightupordoesnotgoout.................................................................40-574

E-19Turnsignalandhazardlampdonotlightupordonotgoout.................................................40-579

E-20Stoplampdoesnotlightuporremainslightingup.................................................................40-586

E-21Backuplampdoesnotlightuporremainslightingup............................................................40-589

E-22Backupalarmdoesnotsoundordoesnotstopsounding......................................................40-592

E-23Horndoesnotsoundordoesnotstopsounding....................................................................40-594

E-24Alarmbuzzerdoesnotsoundordoesnotstopsounding.......................................................40-597

E-25KOMTRAXsystemdoesnotoperatenormally.......................................................................40-599

E-26Fuelgaugedoesnotindicatecorrectlevel.............................................................................40-601

E-27Seatbeltcautionlampindicationisincorrect..........................................................................40-603

Troubleshootingforhydraulicandmechanicalsystem(H-mode).......................................................40-605

Informationdescribedintroubleshootingtable(H-mode)................................................................40-605

Systemchartofhydraulicandmechanicalsystems........................................................................40-606

Failuremodeandcausetable.........................................................................................................40-608

H-1Machinetravelsneitherforwardnorinreverse.........................................................................40-614

H-2Machinedoesnottravelforward(normallytravelsinreverse).................................................40-616

H-3Machinedoesnottravelinreverse(normallytravelsforward).................................................40-617

H-4Bothforwardandreversetravelspeedsarelow......................................................................40-618

H-5Forwardtravelspeedislow(normalwhentravelinginreverse)...............................................40-620

H-6Reversetravelspeedislow(normalwhentravelingforward)..................................................40-621

H-7Machinelackspowerwhentravelingbothforwardandinreverse...........................................40-622

H-8Machinelackspowerwhentravelingforward(normalwhentravelinginreverse)....................40-624

H-9Machinelackspowerwhentravelinginreverse(normalwhentravelingforward)....................40-625

H-10Enginestallsduringtravelorenginespeeddropssignificantly..............................................40-626

H-11Machinedoesnotturn............................................................................................................40-627

H-12Steeringwheelisheavytoturn...............................................................................................40-629

H-13Machineswaysorlargeshocksaremadewhilemachineturns.............................................40-630

H-14Machineturnstoeithersideunintentionallyduringtraveling..................................................40-631

H-15Brakedoesnotworkoritisweak...........................................................................................40-632

H-16Brakeisnotreleasedordrags................................................................................................40-633

H-17Parkingbrakedoesnotworkoritisweak..............................................................................40-634

H-18Parkingbrakeisnotreleasedordrags...................................................................................40-635

H-19Boomdoesnotrise.................................................................................................................40-636

H-20Boommovessloworlacksliftingforce...................................................................................40-637

H-21Boomrisingspeedlowersatcertainheight............................................................................40-638

H-22Liftcylindercannotholddownbucket(bucketrisesoffground).............................................40-639

H-23Hydraulicdriftofboomislarge...............................................................................................40-640

H-24Boomwobblesduringoperation.............................................................................................40-644

H-25Bucketdoesnottiltback.........................................................................................................40-645

H-26Bucketmovessloworlackstiltingbackforce.........................................................................40-646

H-27Bucketspeedlowersintilt-backmotion..................................................................................40-647

H-28Bucketcylindercannotholddownbucket(bucketrisesoffground).......................................40-648

H-29Hydraulicdriftofbucketislarge..............................................................................................40-649

H-30Loadedbucketwobblesduringtravel(withworkequipmentvalveat"HOLD")......................40-650

H-31Boomandbucketcontrolleversdonotmovesmoothlyandareheavytomove....................40-651

H-32Enginespeedlowersremarkablyorenginestallswhileworkequipmentisoperated............40-652

H-33Largeshockismadewhenworkequipmentstartsandstops................................................40-653

H-34Whencertainworkequipmentisrelievedhydraulically,otherworkequipmentmoves..........40-654

H-35ECSSdoesnotoperateandmachinepitchesandbounds....................................................40-655

H-36Fanspeedisabnormal(toohighorlow,orfandoesnotrotate)............................................40-656

H-37Unusualnoiseisheardfromaroundfan.................................................................................40-658

Troubleshootingofengine(S-mode)..................................................................................................40-659

Informationmentionedintroubleshootingtable(Smode)...............................................................40-659

S-1EnginedoesnotcrankwhenstartingswitchisturnedtoSTARTposition................................40-660

S-2Enginecranksbutnoexhaustsmokecomesout.....................................................................40-661

S-3Fuelisbeinginjectedbutenginedoesnotstart(misfiring:enginecranksbutdoesnotstart).40-662

S-4Enginestartabilityispoor..........................................................................................................40-663

S-5Enginedoesnotpickupsmoothly............................................................................................40-665

S-6Enginestopsduringoperation..................................................................................................40-667

S-7Enginerunsroughorisunstable..............................................................................................40-668

S-8Enginelackspower...................................................................................................................40-669

S-9Exhaustsmokeisblack............................................................................................................40-671

S-10Engineoilconsumptionisexcessive......................................................................................40-673

S-11Oilbecomescontaminatedquickly.........................................................................................40-674

S-12Fuelconsumptionisexcessive...............................................................................................40-675

S-13Oilisincoolant(orcoolantspurtsorcoolantlevelgoesdown)..............................................40-676

S-14Oilpressuredrops..................................................................................................................40-677

S-15Fuelmixesintoengineoil.......................................................................................................40-678

S-16Watermixesintoengineoil(milky).........................................................................................40-679

S-17Coolanttemperaturerisestoohigh(overheating)..................................................................40-680

S-18Unusualnoiseisheard...........................................................................................................40-681

S-19Vibrationisexcessive.............................................................................................................40-682

S-20Aircannotbebledfromfuelcircuit.........................................................................................40-683

50Disassemblyandassembly

Generalinformationondisassemblyandassembly...............................................................................50-4

Howtoreadthismanual......................................................................................................................50-4

Coatingmaterialslist...........................................................................................................................50-6

Specialtoollist..................................................................................................................................50-10

Sketchesofspecialtools...................................................................................................................50-14

Engineandcoolingsystem...................................................................................................................50-24

Removalandinstallationoffuelsupplypumpassembly...................................................................50-24

Removalandinstallationoffuelinjectorassembly............................................................................50-28

Removalandinstallationofenginehoodassembly..........................................................................50-36

Removalandinstallationofcylinderheadassembly.........................................................................50-39

Removalandinstallationofradiatorassembly..................................................................................50-51

Removalandinstallationofairaftercoolerassembly........................................................................50-54

Removalandinstallationofhydraulicoilcoolerassembly................................................................50-56

Removalandinstallationofengineassembly...................................................................................50-58

Removalandinstallationofbeltforalternatorandairconditionercompressor.................................50-64

Removalandinstallationofenginefrontoilsealassembly...............................................................50-66

Removalandinstallationofenginerearoilsealassembly................................................................50-70

Removalandinstallationofcoolingfanandfanmotorassembly.....................................................50-74

Removalandinstallationoffueltankassembly................................................................................50-77

RemovalandinstallationofKCCVventilatorassembly....................................................................50-79

RemovalandinstallationofKDOCmuffler........................................................................................50-80

RemovalandinstallationofEGRcoolerassembly...........................................................................50-82

RemovalandinstallationofEGRvalveassembly.............................................................................50-84

Powertrain............................................................................................................................................50-86

Removalandinstallationoftransferassembly..................................................................................50-86

Disassemblyandassemblyoftransferassembly...........................................................................50-90

Removalandinstallationofparkingbrakeassembly......................................................................50-113

Removalandinstallationofparkingbrakecylinderassembly.........................................................50-115

Disassemblyandassemblyofparkingbrakeassembly..................................................................50-116

Removalandinstallationoffrontaxleassembly.............................................................................50-122

Removalandinstallationofrearaxleassembly..............................................................................50-124

Disassemblyandassemblyofaxlehousingassembly....................................................................50-127

Disassemblyandassemblyofdifferentialassembly.......................................................................50-136

Undercarriageandframe....................................................................................................................50-162

Removalandinstallationofcenterhingepin...................................................................................50-162

Removalandinstallationofcounterweightassembly......................................................................50-171

Hydraulicsystem.................................................................................................................................50-174

RemovalandinstallationofHSTpumpandquadrupletypegearpumpassembly.........................50-174

RemovalandinstallationofHSTmotor1assembly........................................................................50-178

RemovalandinstallationofHSTmotor2assembly........................................................................50-180

Removalandinstallationofworkequipmentcontrolvalveassembly..............................................50-183

RemovalandinstallationofECSS(ElectronicallyControlledSuspensionSystem)valveassembly ..................................................................................................................................................50-185

Removalandinstallationofhydraulictankassembly......................................................................50-187

Disassemblyandassemblyofhydrauliccylinderassembly............................................................50-189

Workequipment..................................................................................................................................50-193

Removalandinstallationofworkequipmentassembly...................................................................50-193

Cabanditsattachments.....................................................................................................................50-199

Removalandinstallationofoperator'scabandfloorframeassembly............................................50-199

Removalandinstallationofoperator'scabglass(adheredglass)..................................................50-204

Disassemblyandassemblyofoperator'sseat................................................................................50-212

Removalandinstallationofairconditionerunitassembly...............................................................50-222

Removalandinstallationofairconditionercompressorassembly..................................................50-228

Electricalsystem.................................................................................................................................50-230

Removalandinstallationofmachinemonitor..................................................................................50-230

Removalandinstallationofenginecontrollerassembly..................................................................50-232

RemovalandinstallationofHSTcontrollerassembly.....................................................................50-234 RemovalandinstallationofKOMTRAXterminalassembly.............................................................50-235

60Maintenancestandard

Engineandcoolingsystem....................................................................................................................60-3

Enginemountandtransfermount......................................................................................................60-3

Damper...............................................................................................................................................60-4

Coolingsystem...................................................................................................................................60-5

Coolingfanmotor...............................................................................................................................60-6

Powertrain.............................................................................................................................................60-8

Driveshaft..........................................................................................................................................60-8

Transfer...........................................................................................................................................60-9

Axle..................................................................................................................................................60-17

Differential.......................................................................................................................................60-19

Limitedslipdifferential.....................................................................................................................60-23

Finaldrive........................................................................................................................................60-25

Steeringsystem..................................................................................................................................60-28

Orbitrolvalve...................................................................................................................................60-28

Steeringcylinder..............................................................................................................................60-29

Steeringcolumn...............................................................................................................................60-32

Priorityvalve....................................................................................................................................60-33

Emergencysteeringvalve...............................................................................................................60-34

Brakesystem......................................................................................................................................60-36

Chargevalve...................................................................................................................................60-36

Slackadjuster..................................................................................................................................60-38

Brake...............................................................................................................................................60-39

Parkingbrake..................................................................................................................................60-41

Undercarriageandframe....................................................................................................................60-42

Axlemountandcenterhingepin.....................................................................................................60-42

00-12WA200-7

Workequipmentlinkage..................................................................................................................60-59 Bucket.............................................................................................................................................60-61

80Appendix

Airconditioner.........................................................................................................................................80-3

Functionsofmaincomponentsinairconditionerunit.......................................................................80-10

Blowerandintakeunit.......................................................................................................................80-11 Compressor.......................................................................................................................................80-12 Condenser.........................................................................................................................................80-13

Receiverdrier....................................................................................................................................80-14

Airconditionercontrolpanel..............................................................................................................80-15

Procedurefortroubleshooting...........................................................................................................80-16

Circuitdiagramandarrangementofconnectorpins.........................................................................80-18

Systemdiagram................................................................................................................................80-20

Detailsofairconditionerunit.............................................................................................................80-22

Partsandconnectorslayout..............................................................................................................80-23

Inspectionbyself-diagnosisfunction(displaysdiagnosisonthecontrolpanel)...............................80-25

Testingtemperaturecontrolsystem..................................................................................................80-26

TestingFRESH/RECIRCairchangeover..........................................................................................80-27

Testingevaporatortemperaturesensor............................................................................................80-29

Testingrelays....................................................................................................................................80-30

Troubleshootingchart1.....................................................................................................................80-31

Troubleshootingchart2.....................................................................................................................80-33

Informationdescribedintroubleshootingtable..................................................................................80-36

Troubleshootingforpowersupplysystem(Airconditionerdoesnotoperate)..................................80-37

Troubleshootingforcompressorandrefrigerantsystem(Airisnotcooled)......................................80-41

Troubleshootingforblowermotorsystem(Noaircomesoutorairflowisabnormal)......................80-44

Troubleshootingfortemperaturecontrol...........................................................................................80-47

TroubleshootingforFRESH/RECIRCairchangeover.......................................................................80-50

Connectionofservicetool.................................................................................................................80-52

Troubleshootingbygaugepressure..................................................................................................80-54

Precautionsfordisconnectingandconnectinghosesandtubesinairconditionercircuit.................80-57

Handlingofcompressoroil................................................................................................................80-59

90Diagramsanddrawings

Hydraulicdiagramsanddrawings...........................................................................................................90-3

Symbolsusedinhydrauliccircuitdiagrams........................................................................................90-3

Hydrauliccircuitdiagram.....................................................................................................................90-5

Electricaldiagramsanddrawings...........................................................................................................90-7

Symbolsusedinelectriccircuitdiagrams...........................................................................................90-7

Electricalcircuitdiagram................................................................................................................90-11