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
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
Replacingalternatorbelt...................................................................................................................30-39
Powertrain............................................................................................................................................30-40
Testingoilleakagefromaxlefinaldrive...........................................................................................30-40
Testingdriveshaftforlooseness,backlash,anddamage................................................................30-41
Testingacceleratorpedal.................................................................................................................30-42
TestingandadjustingHSToilpressure............................................................................................30-44
Testingtransferclutchcontrolpressure...........................................................................................30-49
Steeringsystem....................................................................................................................................30-50
Testingdirectionallever....................................................................................................................30-50
Testingandadjustingsteeringwheel...............................................................................................30-51
Testingworkequipmentcontrollever...............................................................................................30-53
Testingandadjustingsteeringcircuitoilpressure............................................................................30-54
Bleedingairfromsteeringcircuit......................................................................................................30-56
Brakesystem.......................................................................................................................................30-57
Testingbrakepedal..........................................................................................................................30-57
Testingandadjustingbrakepedalandlinkage................................................................................30-58
Testingbrakingperformance............................................................................................................30-59
00-4WA200-7
Testingandadjustingaccumulatorchargepressure........................................................................30-60
Testingwheelbrakeoilpressure......................................................................................................30-62
Testingloweringofwheelbrakepressure........................................................................................30-63
Testingwearofwheelbrakedisc.....................................................................................................30-66
Bleedingairfromwheelbrakecircuit...............................................................................................30-67
Releasingremainingpressureinbrakeaccumulatorcircuit.............................................................30-68
Testingparkingbrakeperformance..................................................................................................30-69
Testingparkingbrakereleasepressure...........................................................................................30-70
Methodofreleasingparkingbrakemanually....................................................................................30-71
Hydraulicsystem...................................................................................................................................30-72
Testingandadjustingcoolingfanspeed..........................................................................................30-72
Testingcoolingfanpumpcircuitoilpressure....................................................................................30-73
TestingworkequipmentPPCoilpressure........................................................................................30-74
Testingandadjustingworkequipmentoilpressure..........................................................................30-75
Bleedingairfromeachpart...............................................................................................................30-76
Releasingremainingpressureinhydrauliccircuit.............................................................................30-77
Workequipment....................................................................................................................................30-78
Testingandadjustingbucketpositioner............................................................................................30-78
Testingandadjustingboomkick-outswitch......................................................................................30-79
Checkingtheproximityswitchworkingpilotlamp.............................................................................30-80
Electricalsystem...................................................................................................................................30-81
Adjustingreplaced,reassembledoraddedsensor,controller,etc.withmachinemonitor................30-81
Specialfunctionsofmachinemonitor................................................................................................30-83
KOMTRAXterminalstart-upprocedure..........................................................................................30-137
LampindicationofKOMTRAXterminal...........................................................................................30-140
Handlingvoltagecircuitofcontroller...............................................................................................30-144
Testdiodes......................................................................................................................................30-145
PmClinic.............................................................................................................................................30-146 PmClinicservice.............................................................................................................................30-146
40Troubleshooting
Relatedinformationontroubleshooting..................................................................................................40-8
Pointstorememberwhenperformingtroubleshooting........................................................................40-8
Howtoproceedintroubleshooting....................................................................................................40-10
Checksbeforetroubleshooting..........................................................................................................40-12
Checkprocedurebeforetroubleshooting..........................................................................................40-14
Preparationfortroubleshootingofelectricalsystem.........................................................................40-32
Classificationandproceduresoftroubleshooting..............................................................................40-37
SymptomandtroubleshootingNo.....................................................................................................40-41
Informationdescribedintroubleshootingtable..................................................................................40-43
Procedurefortroubleshootingofopencircuitinwiringharnessofpressuresensorsystem............40-45
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
Failurecode[7RHYKB]GroundFaultofFanMotorEPCSolenoidOutput.....................................40-123
Failurecode[7RHYKY]HotShortofFanMotorEPCSolenoidOutput..........................................40-125
Failurecode[989FN1]TravelSpeedOverrunAlarm......................................................................40-127
WA200-700-5
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[CA322]Injector#1(L#1)Open/ShortError...............................................................40-169 Failurecode[CA324]Injector#3(L#3)Open/ShortError...............................................................40-171 Failurecode[CA331]Injector#2(L#2)Open/ShortError...............................................................40-173 Failurecode[CA332]Injector#4(L#4)Open/ShortError...............................................................40-175 Failurecode[CA343]EngineControllerInternalFailure.................................................................40-177 Failurecode[CA351]InjectorsDriveCircuitError...........................................................................40-178 Failurecode[CA352]Sensor1SupplyVoltageLowError..............................................................40-179 Failurecode[CA356]MassAirFlowSensorHighError.................................................................40-181 Failurecode[CA357]MassAirFlowSensorLowError..................................................................40-183 Failurecode[CA386]Sensor1SupplyVoltageHighError.............................................................40-185 Failurecode[CA428]WaterinFuelSensorHighError...................................................................40-186 Failurecode[CA429]WaterinFuelSensorLowError...................................................................40-188 Failurecode[CA431]IdleValidationSwError................................................................................40-190 Failurecode[CA432]IdleValidationProcessError........................................................................40-193 Failurecode[CA435]EngineOilPressureSwError.......................................................................40-195 Failurecode[CA441]BatteryVoltageLowError.............................................................................40-196 Failurecode[CA442]BatteryVoltageHighError............................................................................40-198 Failurecode[CA449]RailPressVeryHighError............................................................................40-199 Failurecode[CA451]CommonRailPressureSensorHighError...................................................40-200 Failurecode[CA452]CommonRailPressureSensorLowError....................................................40-202 Failurecode[CA466]KVGTMotorDriverPositionError................................................................40-204 Failurecode[CA488]ChgAirTempHighTorqueDerate...............................................................40-206 Failurecode[CA515]RailPressureSensorSupVoltHighError....................................................40-207 Failurecode[CA516]RailPressureSensorSupVoltLowError.....................................................40-209 Failurecode[CA553]CommonRailPressureHighError1............................................................40-211 Failurecode[CA555]CrankcasePressHighError1......................................................................40-212 Failurecode[CA556]CrankcasePressHighError2......................................................................40-213 Failurecode[CA559]RailPressLowError1..................................................................................40-214 Failurecode[CA689]EngineNeSpeedSensorError....................................................................40-217 Failurecode[CA691]IntakeAirTempSensHighError..................................................................40-219
Failurecode[CA692]IntakeAirTempSensLowError..................................................................40-221
Failurecode[CA697]ECMInternalTemperatureSensorHighError.............................................40-223
Failurecode[CA698]EMCInternalTemperatureSensorLowError..............................................40-224
Failurecode[CA731]EngineBkupSpeedSensorPhaseError.....................................................40-225 Failurecode[CA778]EngineBkupSpeedSensorError................................................................40-227 Failurecode[CA1117]PersistentDataLostError..........................................................................40-232
Failurecode[CA1695]Sensor5SupplyVoltageHighError...........................................................40-233
Failurecode[CA1696]Sensor5SupplyVoltageLowError...........................................................40-234
Failurecode[CA1843]CrankcasePressSensHighError..............................................................40-235 Failurecode[CA1844]CrankcasePressSensLowError..............................................................40-237 Failurecode[CA1896]EGRValveStuckError...............................................................................40-239 Failurecode[CA1942]CrankcasePressSensIn-RangeError......................................................40-240
Failurecode[CA1961]EGRMotorDriverICOverTempError......................................................40-241 Failurecode[CA2185]ThrottleSensorSupplyVoltageHighError................................................40-242 Failurecode[CA2186]ThrottleSensorSupplyVoltageLowError.................................................40-244 Failurecode[CA2249]RailPressLowError2................................................................................40-246 Failurecode[CA2272]EGRValvePositionSensorLowError.......................................................40-247 Failurecode[CA2311]IMVSolenoidError.....................................................................................40-249 Failurecode[CA2349]EGRValveSolenoidOpenCircuitError.....................................................40-250 Failurecode[CA2353]EGRValveSolenoidShortCircuitError.....................................................40-252 Failurecode[CA2357]EGRValveServoError..............................................................................40-254 Failurecode[CA2373]ExhaustManifoldPressureSensorHighError...........................................40-255 Failurecode[CA2374]ExhaustManifoldPressureSensorLowError............................................40-257 Failurecode[CA2375]EGROrificeTemperatureSensorHighError.............................................40-259 Failurecode[CA2376]EGROrificeTemperatureSensorLowError..............................................40-261 Failurecode[CA2554]ExhaustManifoldPressureSensorIn-RangeError...................................40-263 Failurecode[CA2555]GridHeaterRelayVoltageLowError.........................................................40-264 Failurecode[CA2556]GridHeaterRelayVoltageHighError........................................................40-266 Failurecode[CA2961]EGROrificeTemperatureHighError1......................................................40-268 Failurecode[CA2973]ChargeAirPressureSensorIn-RangeError..............................................40-269 Failurecode[CA3419]MassAirFlowSensorSupVoltHighError.................................................40-270 Failurecode[CA3421]MassAirFlowSensorSupVoltLowError.................................................40-272 Failurecode[CA3724]EGR/KVGTMotorDriverPowerLowError................................................40-274 Failurecode[CA3741]CommonRailPressureValveTripError....................................................40-276 Failurecode[CA3918]KVGTStuckError.......................................................................................40-277 Failurecode[CA3919]KVGTMotorDriverICOverTemperatureError.........................................40-278 Failurecode[CA3921]KVGTServoError2...................................................................................40-279 Failurecode[CA3922]KVGTMotorDriverOpenError..................................................................40-280 Failurecode[CA3923]KVGTMotorDriverShortError..................................................................40-282 Failurecode[D110L4]DisconnectionorShorttoGroundofBatteryRelaySignalLine.................40-284 Failurecode[D160KA]DisconnectionofBackupLampRelayOutput............................................40-286 Failurecode[D160KB]GroundFaultofBackupLampRelayOutput.............................................40-288 Failurecode[D160KY]HotShortofBackupLampRelayOutput...................................................40-290 Failurecode[D191KA]DisconnectionofNeutralOutputRelay......................................................40-292 Failurecode[D191KB]GroundFaultofNeutralOutputRelay........................................................40-294 Failurecode[D191KY]HotShortofNeutralOutputRelay.............................................................40-296 Failurecode[D192KA]DisconnectionofECSSSolenoidRelay.....................................................40-298 Failurecode[D192KB]GroundFaultofECSSSolenoidRelay......................................................40-300 Failurecode[D192KY]HotShortofECSSSolenoidRelay............................................................40-302 Failurecode[D1B0KA]DisconnectionofHSTSafetyRelay...........................................................40-304 Failurecode[D1B0KB]GroundFaultofHSTSafetyRelay............................................................40-306 Failurecode[D1B0KY]HotShortofHSTSafetyRelay..................................................................40-308 Failurecode[D1B0MC]MalfunctionofHSTSafetyRelay..............................................................40-310 Failurecode[D1E6KA]DisconnectionofParkingBrakeRelay......................................................40-311 Failurecode[D1E6KB]GroundFaultofParkingBrakeRelay........................................................40-313 Failurecode[D1E6KY]HotShortofParkingBrakeRelay..............................................................40-315
Failurecode[D5ZHKA]FailureofKeySWCSignal.......................................................................40-317 Failurecode[D5ZHKB]KeySWCSignalHotShortCircuit............................................................40-319 Failurecode[D5ZHL6]DisconnectionofKeySWC.......................................................................40-321 Failurecode[DAF3KK]ControllerPowerSourceLow(MON)........................................................40-323 Failurecode[DAF5KP]5VSensorPowerSupply:GroundFault...................................................40-325 Failurecode[DAF6KP]24VSensorPowerSupply:GroundFault.................................................40-327 Failurecode[DAFRKR]MachineMonitorCAN2CommunicationError(MachineMonitor)............40-329 Failurecode[DAJ0KK]ControllerPowerSourceLow(HST)..........................................................40-330 Failurecode[DAJ0KT]AbnormalityofNon-volatileMemory(HST)................................................40-333 Failurecode[DAJ0MC]HSTControllerMalfunction.......................................................................40-334 Failurecode[DAJ1KA]DisconnectionofKeySWACC(HST).......................................................40-335 Failurecode[DAJ2KK]SolenoidPowerSourceLow(HST)...........................................................40-337 Failurecode[DAJ4KB]GroundFaultofSolenoidSelf-HoldingRelay(HST)..................................40-340 Failurecode[DAJ4KZ]FailureofSolenoidSelf-HoldingRelay(HST)............................................40-342 Failurecode[DAJ5KX]Failureof5VPowerSource0(HST).........................................................40-344 Failurecode[DAJ6KX]Failureof5VPowerSource1(HST).........................................................40-346 Failurecode[DAJ9KQ]InconsistencyofModelSelection(HST)....................................................40-348 Failurecode[DAJLKA]OperatingLampOpenCircuit(HST)..........................................................40-349 Failurecode[DAJLKB]OperatingLampShortCircuit(HST)..........................................................40-351 Failurecode[DAJQKR]CAN2Disconnection(HST)......................................................................40-353 Failurecode[DAJRMA]InconsistencyofOptionSelection(HST)..................................................40-354 Failurecode[DB2QKR]CAN2Disconnection(EngineController)..................................................40-355 Failurecode[DB2RKR]CAN1Disconnection(EngineController)..................................................40-359 Failurecode[DBE6KX]24VOutputPowerSupplySystemFailure................................................40-362 Failurecode[DD1NL4]FanAutoReverseSwitchSignalError......................................................40-364 Failurecode[DD1NLD]FanReverseSwitchSignal:Abnormal......................................................40-366 Failurecode[DDB6L4]ParkingBrakeSignalMalfunction..............................................................40-368 Failurecode[DDD7KA]FailureofVariableSpeedControl.............................................................40-370 Failurecode[DDD7KY]HotShortofVariableSpeedControl.........................................................40-372 Failurecode[DDE5MA]DisconnectionofSteeringOilPressureSwitch(EmergencySteeringControl Switch).......................................................................................................................................40-374 Failurecode[DDK3KA]FNRSWInputSignalDisconnection.........................................................40-376 Failurecode[DDK3KB]FNRSWInputSignalShortCircuit...........................................................40-378 Failurecode[DDK6KA]FNRLeverInputSignalDisconnection.....................................................40-380 Failurecode[DDK6KY]FNRLeverInputSignalDisconnection(HotShort)...................................40-382 Failurecode[DDNRLD]GroundFaultofWorkEquipmentLockSwitch.........................................40-384 Failurecode[DDS5L6]LowSteeringOilPressure(EmergencySteeringControl).........................40-386 Failurecode[DF10KA]DisconnectionofSpeedRangeInputSwitch.............................................40-388 Failurecode[DF10KB]DisconnectionofSpeedRangeSelectorSwitch(HotShort).....................40-393 Failurecode[DGH1KX]HSTOilTemperatureSensorShorttoGround.........................................40-398 Failurecode[DGR2KB]GroundFaultofBrakeOilTemperatureSensor.......................................40-400 Failurecode[DGR2KZ]FailureofBrakeOilTemperatureSensor.................................................40-402 Failurecode[DHH1KX]FailureofHSTOilPressureSensor..........................................................40-404 Failurecode[DHH1KY]HotShortofHSTOilPressureSensor......................................................40-406 Failurecode[DHPCKX]FailureofBoomPressureSensor(Bottom)..............................................40-408 Failurecode[DHPDKX]FailureofBoomPressureSensor(Head).................................................40-410 Failurecode[DHTCL6]HSTOilFilterCloggingDetectionFailure..................................................40-412 Failurecode[DJF1KA]DisconnectionorHotShortCircuitofFuelLevelSensor...........................40-414 Failurecode[DK5DKA]Failureof3rdLeverPotentiometerSensor(Main)....................................40-416 Failurecode[DK5DKY]HotShortof3rdLeverPotentiometerSensor(Main)................................40-419 Failurecode[DK5DL8]3rdLeverPotentiometerSensor(Main&Sub)Disagree...........................40-421 Failurecode[DK5EKA]Failureof3rdLeverPotentiometerSensor(Sub)......................................40-424 Failurecode[DK5EKY]HotShortof3rdLeverPotentiometerSensor(Sub)..................................40-427 Failurecode[DKA0KX]FailureofBoomAngleSensor...................................................................40-429 Failurecode[DLM3KA]FailureofCoolingFanSpeedSensor.......................................................40-431 Failurecode[DLM3LC]GroundFaultofCoolingFanSpeedSensor.............................................40-433
00-8WA200-7
Failurecode[DLT3KX]VehicleSpeedSensorCircuitFailure(B)..................................................40-434 Failurecode[DLT4KX]VehicleSpeedSensorCircuitFailure(A)..................................................40-436 Failurecode[DLT4L0]VehicleSpeedSensorFailure(A&B)........................................................40-438 Failurecode[DLT4LC]VehicleSpeedSensorFailure(AorB)......................................................40-441 Failurecode[DT22KB]GroundFaultofWorkEquip.LockIndicator..............................................40-443 Failurecode[DV00KY]HotShortofAlarmBuzzer.........................................................................40-445 Failurecode[DW26KA]OpenCircuitofMotor2Solenoid..............................................................40-447 Failurecode[DW26KB]GroundFaultofMotor2Solenoid.............................................................40-449 Failurecode[DW26KY]HotShortofMotor2Solenoid..................................................................40-451 Failurecode[DW44KA]OpenCircuitofDirectionalPressureSelectionSolenoid..........................40-453 Failurecode[DW44KB]GroundFaultofDirectionalPressureSelectionSolenoid.........................40-455 Failurecode[DW44KY]HotShortofDirectionalPressureSelectionSolenoid..............................40-457 Failurecode[DX19KA]DisconnectionofMotor1Solenoid............................................................40-459 Failurecode[DX19KB]GroundFaultofMotor1Solenoid..............................................................40-462 Failurecode[DX19KY]HotShortofMotor1Solenoid...................................................................40-464 Failurecode[DX20KA]DisconnectionofClutchEPCSolenoid......................................................40-466 Failurecode[DX20KB]GroundFaultofClutchEPCSolenoid.......................................................40-469 Failurecode[DX20KY]HotShortofClutchEPCSolenoid.............................................................40-471 Failurecode[DXH7KA]DisconnectionofReverseSolenoid..........................................................40-473 Failurecode[DXH7KB]GroundFaultofReverseSolenoid............................................................40-475 Failurecode[DXH7KY]HotShortofReverseSolenoid..................................................................40-477 Failurecode[DXH8KA]DisconnectionofForwardSolenoid..........................................................40-478 Failurecode[DXH8KB]GroundFaultofForwardSolenoid............................................................40-480 Failurecode[DXH8KY]HotShortofForwardSolenoid..................................................................40-482 Failurecode[DXHJKA]Disconnectionof3rdEPCSolenoid(EXT)................................................40-483 Failurecode[DXHJKB]GroundFaultof3rdEPCSolenoid(EXT).................................................40-485 Failurecode[DXHJKY]HotShortof3rdEPCSolenoid(EXT).......................................................40-487 Failurecode[DXHKKA]Disconnectionof3rdEPCSolenoid(RET)...............................................40-488 Failurecode[DXHKKB]GroundFaultof3rdEPCSolenoid(RET).................................................40-490 Failurecode[DXHKKY]HotShortof3rdEPCSolenoid(RET)......................................................40-492 Failurecode[H2K0KA]FailureofQuickCouplerLockSignal........................................................40-493 Failurecode[H2K0KY]HotShortofQuickCouplerLockSignal....................................................40-496 Failurecode[J141N1]SteeringPumpOverRun............................................................................40-498 Failurecode[LA00L3]FailureofFanReverse................................................................................40-499 Failurecode[M100N1]HSTPumpOverRun.................................................................................40-500 Failurecode[M400N1]HSTMotor1OverRun..............................................................................40-501 Troubleshootingofelectricalsystem(E-mode)...................................................................................40-502
E-1Enginedoesnotstart................................................................................................................40-502
E-2Manualpreheatingsystemdoesnotwork................................................................................40-507
E-3Automaticpreheatingsystemdoesnotwork............................................................................40-510
E-4Whilepreheatingisworking,preheatingmonitordoesnotlightup..........................................40-512
E-5WhenstartingswitchisturnedtoONposition,nothingisdisplayedonmachinemonitor........40-514
E-6Travelspeedisslow.................................................................................................................40-517
E-7ECSSdoesnotoperate............................................................................................................40-519
E-8ECSSremainsbeingoperated.................................................................................................40-522
E-9Boomkick-outdoesnotworkorisnotreset.............................................................................40-525
E-10Bucketpositionerdoesnotworkorisnotreset......................................................................40-528
E-11BoomFLOATholdingdoesnotworkorisnotreset...............................................................40-531
E-12Directionalselectiondoesnotworknormally..........................................................................40-534
E-13Fandoesnotrotateinreverse................................................................................................40-545
E-14Fanremainsinreverserotationmode....................................................................................40-548
E-15Wipersdonotoperate............................................................................................................40-550
E-16Windowwasherdoesnotoperate..........................................................................................40-555
E-17Headlamp,clearancelamp,taillamporlicense-platelampdoesnotlightupordoesnotgoout ..................................................................................................................................................40-558
E-18Workinglampdoesnotlightupordoesnotgoout................................................................40-567
E-19Turnsignalandhazardlampdonotlightupordonotgoout.................................................40-572
E-20Stoplampdoesnotlightuporremainslightingup.................................................................40-579
E-21Backuplampdoesnotlightuporremainslightingup............................................................40-582
E-22Backupalarmdoesnotsoundordoesnotstopsounding......................................................40-585
E-23Horndoesnotsoundordoesnotstopsounding....................................................................40-587
E-24Alarmbuzzerdoesnotsoundordoesnotstopsounding.......................................................40-590
E-25KOMTRAXsystemdoesnotoperatenormally.......................................................................40-592
E-26Fuelgaugedoesnotindicatecorrectlevel.............................................................................40-594
E-27Seatbeltcautionlampindicationisincorrect..........................................................................40-596
Troubleshootingforhydraulicandmechanicalsystem(H-mode).......................................................40-597
Informationdescribedintroubleshootingtable(H-mode)................................................................40-597
Systemchartofhydraulicandmechanicalsystems........................................................................40-598
Failuremodeandcausetable.........................................................................................................40-600
H-1Machinetravelsneitherforwardnorinreverse.........................................................................40-606
H-2Machinedoesnottravelforward(normallytravelsinreverse).................................................40-608
H-3Machinedoesnottravelinreverse(normallytravelsforward).................................................40-609
H-4Bothforwardandreversetravelspeedsarelow......................................................................40-610
H-5Forwardtravelspeedislow(normalwhentravelinginreverse)...............................................40-612
H-6Reversetravelspeedislow(normalwhentravelingforward)..................................................40-613
H-7Machinelackspowerwhentravelingbothforwardandinreverse...........................................40-614
H-8Machinelackspowerwhentravelingforward(normalwhentravelinginreverse)....................40-616
H-9Machinelackspowerwhentravelinginreverse(normalwhentravelingforward)....................40-617
H-10Enginestallsduringtravelorenginespeeddropssignificantly..............................................40-618
H-11Machinedoesnotturn............................................................................................................40-619
H-12Steeringwheelisheavytoturn...............................................................................................40-621
H-13Machineswaysorlargeshocksaremadewhilemachineturns.............................................40-622
H-14Machineturnstoeithersideunintentionallyduringtraveling..................................................40-623
H-15Brakedoesnotworkoritisweak...........................................................................................40-624
H-16Brakeisnotreleasedordrags................................................................................................40-625
H-17Parkingbrakedoesnotworkoritisweak..............................................................................40-626
H-18Parkingbrakeisnotreleasedordrags...................................................................................40-627
H-19Boomdoesnotrise.................................................................................................................40-628
H-20Boommovessloworlacksliftingforce...................................................................................40-629
H-21Boomrisingspeedlowersatcertainheight............................................................................40-630
H-22Liftcylindercannotholddownbucket(bucketrisesoffground).............................................40-631
H-23Hydraulicdriftofboomislarge...............................................................................................40-632
H-24Boomwobblesduringoperation.............................................................................................40-636
H-25Bucketdoesnottiltback.........................................................................................................40-637
H-26Bucketmovessloworlackstiltingbackforce.........................................................................40-638
H-27Bucketspeedlowersintilt-backmotion..................................................................................40-639
H-28Bucketcylindercannotholddownbucket(bucketrisesoffground).......................................40-640
H-29Hydraulicdriftofbucketislarge..............................................................................................40-641
H-30Loadedbucketwobblesduringtravel(withworkequipmentvalveat"HOLD")......................40-642
H-31Boomandbucketcontrolleversdonotmovesmoothlyandareheavytomove....................40-643
H-32Enginespeedlowersremarkablyorenginestallswhileworkequipmentisoperated............40-644
H-33Largeshockismadewhenworkequipmentstartsandstops................................................40-645
H-34Whencertainworkequipmentisrelievedhydraulically,otherworkequipmentmoves..........40-646
H-35ECSSdoesnotoperateandmachinepitchesandbounds....................................................40-647
H-36Fanspeedisabnormal(toohighorlow,orfandoesnotrotate)............................................40-648
H-37Unusualnoiseisheardfromaroundfan.................................................................................40-650
Troubleshootingofengine(S-mode)...................................................................................................40-651
Informationmentionedintroubleshootingtable(Smode)...............................................................40-651
S-1EnginedoesnotcrankwhenstartingswitchisturnedtoSTARTposition................................40-652
S-2Enginecranksbutnoexhaustsmokecomesout.....................................................................40-653
S-3Fuelisbeinginjectedbutenginedoesnotstart(misfiring:enginecranksbutdoesnotstart)..40-654
S-4Enginestartabilityispoor..........................................................................................................40-655
S-5Enginedoesnotpickupsmoothly............................................................................................40-657
S-6Enginestopsduringoperation..................................................................................................40-659
S-7Enginerunsroughorisunstable..............................................................................................40-660
S-8Enginelackspower...................................................................................................................40-661
S-9Exhaustsmokeisblack............................................................................................................40-663
S-10Engineoilconsumptionisexcessive......................................................................................40-665
S-11Oilbecomescontaminatedquickly.........................................................................................40-666
S-12Fuelconsumptionisexcessive...............................................................................................40-667
S-13Oilisincoolant(orcoolantspurtsorcoolantlevelgoesdown)..............................................40-668
S-14Oilpressuredrops..................................................................................................................40-669
S-15Fuelmixesintoengineoil.......................................................................................................40-670
S-16Watermixesintoengineoil(milky).........................................................................................40-671
S-17Coolanttemperaturerisestoohigh(overheating)..................................................................40-672
S-18Unusualnoiseisheard...........................................................................................................40-673
S-19Vibrationisexcessive.............................................................................................................40-674
S-20Aircannotbebledfromfuelcircuit.........................................................................................40-675
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..................................................................................50-50
Removalandinstallationofairaftercoolerassembly........................................................................50-53
Removalandinstallationofhydraulicoilcoolerassembly................................................................50-55
Removalandinstallationofengineassembly...................................................................................50-57
Removalandinstallationofbeltforalternatorandairconditionercompressor.................................50-62
Removalandinstallationofenginefrontoilsealassembly...............................................................50-64
Removalandinstallationofenginerearoilsealassembly................................................................50-68
Removalandinstallationofcoolingfanandfanmotorassembly.....................................................50-72
Removalandinstallationoffueltankassembly................................................................................50-75
RemovalandinstallationofKCCVventilatorassembly....................................................................50-77
RemovalandinstallationofKDOCmuffler........................................................................................50-78
RemovalandinstallationofEGRcoolerassembly...........................................................................50-79
RemovalandinstallationofEGRvalveassembly.............................................................................50-81
Powertrain............................................................................................................................................50-83
Removalandinstallationoftransferassembly..................................................................................50-83
Disassemblyandassemblyoftransferassembly.............................................................................50-87
Removalandinstallationofparkingbrakeassembly......................................................................50-110
Removalandinstallationofparkingbrakecylinderassembly.........................................................50-112
Disassemblyandassemblyofparkingbrakeassembly..................................................................50-113
Removalandinstallationoffrontaxleassembly.............................................................................50-119
Removalandinstallationofrearaxleassembly..............................................................................50-121
Disassemblyandassemblyofaxlehousingassembly...................................................................50-124
Disassemblyandassemblyofdifferentialassembly.......................................................................50-133
Undercarriageandframe....................................................................................................................50-158
Removalandinstallationofcenterhingepin...................................................................................50-158
Removalandinstallationofcounterweightassembly......................................................................50-167
Hydraulicsystem.................................................................................................................................50-170
WA200-700-11
RemovalandinstallationofHSTpumpandquadrupletypegearpumpassembly.........................50-170
RemovalandinstallationofHSTmotor1assembly........................................................................50-174
RemovalandinstallationofHSTmotor2assembly........................................................................50-176
Removalandinstallationofworkequipmentcontrolvalveassembly..............................................50-179
RemovalandinstallationofECSS(ElectronicallyControlledSuspensionSystem)valveassembly ..................................................................................................................................................50-181
Removalandinstallationofhydraulictankassembly......................................................................50-183
Disassemblyandassemblyofhydrauliccylinderassembly............................................................50-185
Workequipment..................................................................................................................................50-189
Removalandinstallationofworkequipmentassembly...................................................................50-189
Cabanditsattachments.....................................................................................................................50-195
Removalandinstallationofoperator'scabandfloorframeassembly............................................50-195
Removalandinstallationofoperator'scabglass(adheredglass)..................................................50-200
Disassemblyandassemblyofoperator'sseat................................................................................50-208
Removalandinstallationofairconditionerunitassembly...............................................................50-218
Removalandinstallationofairconditionercompressorassembly..................................................50-224
Electricalsystem.................................................................................................................................50-226
Removalandinstallationofmachinemonitor..................................................................................50-226
Removalandinstallationofenginecontrollerassembly..................................................................50-228
RemovalandinstallationofHSTcontrollerassembly.....................................................................50-230
RemovalandinstallationofKOMTRAXterminalassembly.............................................................50-231
60Maintenancestandard
Engineandcoolingsystem....................................................................................................................60-3
00-12WA200-7
80Appendix
Airconditioner.........................................................................................................................................80-3 Precautionsforrefrigerant...................................................................................................................80-3 Airconditionercomponent...................................................................................................................80-4
Configurationandfunctionofrefrigerationcycle.................................................................................80-6
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
Index...........................................................................................................................................................1