Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-11 PDF DOWNLOAD

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Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-11 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-11 –  PDF DOWNLOAD

Language : English
Pages : 3282
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-11 –  PDF DOWNLOAD

• SERIAL NUMBERS 85001 and up

Cover 1
00 Index and Foreword . 3
Index . 4
Abbreviation List . 22
Foreword, Safety, Basic Information . 28
How to Read the Shop Manual . 28
Safety Notice for Operation . 30
Precautions to Prevent Fire . 38
Procedures If Fire Occurs . 40
Precautions for Disposing of Waste Materials 41
Procedures for Exhaust Gas Regulations 42
Precautions for DEF . 43
General Character and Precautions for Handling 43
Precautions for Adding 43
Precautions for Storage . 43
Precautions for Fire Hazard and Leakage . 43
Other Precautions . 43
Store DEF . 44
Precautions When You Handle Hydraulic Equipment . 45
Precautions When You Disconnect and Connect Pipings . 48
Precautions When You Handle Electrical Equipment 55
Precautions When You Handle Fuel System Equipment . 57
Precautions When You Handle Intake System Equipment . 58
Practical Use of KOMTRAX 59
Disconnect and Connect Push-Pull Type Coupler . 60
How to Disconnect and Connect Type 1 Push-Pull Type Coupler . 60
How to Disconnect and Connect Type 2 Push-Pull Type Coupler . 61
How to Disconnect and Connect Type 3 Push-Pull Type Coupler . 62
Precautions for Disconnection and Connection of Connectors 64
How to Disconnect and Connect Deutsch Connector . 68
How to Disconnect and Connect Slide Lock Type Connector . 69
How to Disconnect and Connect Connector with Lock to Pull . 71
How to Disconnect and Connect Connector with Lock to Push . 72
How to Disconnect and Connect Connector with Housing to Rotate 74
How to Read the Codes for Electric Cable 75
Explanation of Terms for Maintenance Standard . 79
Standard Tightening Torque Table 82
Conversion Table 89
01 Specifications . 95
Table of Contents . 96
Abbreviation List . 97
Specifications 103
Specification Drawing . 103
Specification Drawing: WA200-8 103
Specifications 105
Specification: WA200-8 105
Weight Table 111
Weight Table: WA200-8 . 111
Fuel, Coolant, Lubricants (For North America) . 113
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 113
Fuel, Coolant, Lubricants (For European Union) 115
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 115
10 Structure and Function . 117
Table of Contents . 118
Abbreviation List . 122
Urea SCR System . 128
Layout Drawing of Urea SCR System . 128
Urea SCR System Diagram . 130
Function of Urea SCR System . 131
Function of DEF System 131
Inducement Strategy . 134
Component Parts of Urea SCR System 148
DEF Mixing Tube . 148
SCR Assembly 149
DEF Tank 151
DEF Pump 153
DEF Injector 154
DEF Hose 155
DEF Tank Heating Valve 156
Boot-up System 157
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 157
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) . 159
System Operating Lamp System 161
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 161
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) . 161
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 161
Function of System Operating Lamp System (Machine with Gateway Function Controller) . 162
Battery Disconnect Switch . 164
Function of Battery Disconnect Switch . 164
Preheating System . 165
System Diagram of Preheating System . 165
Function of Automatic Preheating System . 165
Operation of Automatic Preheating System 165
Function of Manual Preheating System 166
Operation of Manual Preheating System . 166
Engine System . 167
Layout Drawing of Engine System . 167
Function of Engine System . 168
Engine Control System . 169
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) . 169
System Diagram of Engine Control System (Machine with Gateway Function Controller) 171
Function of Engine Control System (Machine with KOMTRAX Terminal) . 173
Function of Engine Control System (Machine with Gateway Function Controller) 174
Operation of Engine Control System (Machine with KOMTRAX Terminal) 177
Operation of Engine Control System (Machine with Gateway Function Controller) . 179
Automatic Idle Stop System 181
Function of Automatic Idle Stop System 181
Component Parts of Engine System 182
Damper 182
VGT . 183
EGR System 186
EGR Valve . 188
EGR Cooler 190
KCCV System . 192
KCCV Ventilator . 194
KDOC 196
Cooling System 199
Layout Drawing of Cooling System 199
Specifications of Cooling System 200
Cooling Fan Control System 201
System Diagram of Cooling Fan Control System 201
Function of Cooling Fan Control System 201
Component Parts of Cooling System . 206
Cooling Fan Motor . 206
Hydraulic Oil Cooler Bypass Valve . 216
Control System 217
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 217
Layout Drawing of Control System (Machine with Gateway Function Controller) . 219
Machine Monitor System 221
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 221
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) . 222
Function of Machine Monitor System 222
Rearview Monitor System . 224
System Diagram of Rearview Monitor System . 224
Function of Rearview Monitor System . 224
KOMTRAX System 225
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 225
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) . 225
Function of KOMTRAX System (Machine with KOMTRAX Terminal) 226
Function of KOMTRAX System (Machine with Gateway Function Controller) . 226
Component Parts of Control System . 227
Machine Monitor . 227
Switch Panel 244
Rearview Monitor 245
Rearview Camera . 247
KOMTRAX Terminal 248
Gateway Function Controller . 250
Communication Terminal 253
Monitor Controller 255
HST Controller 260
CAN Terminating Resistor 265
Engine Controller . 266
Accelerator Pedal . 273
Hydraulic System 275
Layout Drawing of Hydraulic System 275
Component Parts of Hydraulic System . 276
Hydraulic Tank 276
Hydraulic Oil Filter 278
Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump 279
Control Valve . 281
Power Train System 302
Layout Drawing of Power Train System 302
Operation of Power Train System . 304
Directional Selector Switch Control Function 305
HST Control System 307
System Diagram of HST Control System 307
Engine Overrun Prevention Function 308
Neutralizer Function 308
Secondary HST Travel Function . 308
HST Charge System . 309
System Diagram of HST Charge System . 309
Function of HST Charge System . 309
HST Pump Control System . 310
System Diagram of HST Pump Control System . 310
Directional Selection Function 310
Inching Control Function 310
Travel Speed Adjustment Function (at Low Speed) . 311
HST Controller Gear Shift Control Function 312
Gear Shift Function . 312
Gear Shift Display Function . 314
Travel Speed Adjustment Function 314
Transfer Clutch Control Function 315
HST System Protection Function 316
Direction Protection Function . 316
HST Motor 1 Overrun Prevention Function 1 . 316
HST Motor 1 Overrun Prevention Function 2 . 317
Travel Speed Limitation Function 317
Komatsu Traction Control System (KTCS) 318
Komatsu Traction Control System (KTCS) Diagram 318
Function of Komatsu Traction Control System (KTCS) 318
Component Parts of Power Train System . 322
Drive Shaft . 322
HST Pump 324
HST Charge Pump . 332
HST Motor . 334
Transfer 343
Axle 351
Torque Proportioning Differential . 353
Limited Slip Differential . 357
Final Drive . 361
Combination Switch 363
Work Equipment System . 367
Layout Drawing of Work Equipment System . 367
Work Equipment Control System . 369
Work Equipment Lever Operation Function . 369
Work Equipment Lock System 370
Work Equipment Lock System Diagram 370
Function of Work Equipment Lock System 370
Bucket Positioner System 372
Bucket Positioner System Diagram 372
Function of Bucket Positioner System 372
Operation of Bucket Positioner System . 373
Boom Kick-out System 375
System Drawing of Boom Kick-out System 375
Function of Boom Kick-out System 375
Operation of Boom Kick-out System . 376
ECSS 378
ECSS Diagram 378
Function of ECSS 378
Operation of ECSS . 378
Component Parts of Work Equipment System 380
Work Equipment Lock Solenoid Valve 380
Attachment EPC Solenoid Valve . 381
Pilot Circuit Accumulator . 382
ECSS Circuit Accumulator 383
Multifunction Mono-Lever 384
Multifunction Mono-Lever PPC Valve 386
Quick Coupler Solenoid Valve 391
Steering System . 392
Layout Drawing of Steering System . 392
Steering Column . 393
Structure of Steering Column 393
Component Parts of Steering System 394
Priority Valve 394
Orbitrol Valve 397
Cushion Valve . 404
2-Way Restrictor Valve 406
Secondary Steering Valve 407
Brake System 410
Layout Drawing of Brake System 410
Parking Brake Control System 412
System Diagram of Parking Brake Control System 412
Operation of Parking Brake Control System . 412
Component Parts of Brake System . 415
Brake Circuit Accumulator Charge Valve 415
Brake Circuit Accumulator . 419
Parking Brake Solenoid Valve 421
Brake Valve . 423
Slack Adjuster 427
Brake . 429
Parking Brake . 432
Parking Brake Cylinder 434
Undercarriage and Frame . 435
Frame, Axle Mount and Center Hinge Pin 435
Structure of Frame, Axle Mount and Center Hinge Pin . 435
Function of Frame, Axle Mount and Center Hinge Pin 436
Tires . 438
Features of Radial Tire When Compared with Bias Tire 438
Structure of Radial Tire 438
Function of Radial Tire . 439
Structure of Bias Tire 439
Function of Bias Tire . 439
Work Equipment 440
Structure of Work Equipment . 440
Structure of Bucket . 441
CAB Related Parts . 442
ROPS CAB 442
Structure of ROPS CAB (Machine with KOMTRAX Terminal) . 442
Structure of ROPS CAB (Machine with Gateway Function Controller) 443
Function of ROPS CAB 443
CAB Mount . 444
Structure of CAB Mount 444
Function of CAB Mount . 444
20 Standard Value Table . 445
Table of Contents . 446
Abbreviation List . 447
Standard Value Table for Engine . 453
Standard Value Table for Engine: WA200-8 453
Standard Value Table for Machine 458
Standard Value Table for Machine: WA200-8 . 458
Machine Posture and Procedures to Measure Performance . 470
30 Testing and Adjusting 473
Table of Contents . 474
Precautions Before Work . 478
Abbreviation List . 479
Related Information on Testing and Adjusting 485
Tools for Testing and Adjusting . 485
Engine and Cooling System . 494
Examine Engine Speed 494
How to Examine Engine Speed . 494
Examine Boost Pressure 498
How to Examine Boost Pressure on Machine Monitor 498
How to Examine Boost Pressure by Testing Tool . 499
Examine Exhaust Gas Color . 501
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 501
How to Examine Exhaust Gas Color with Smoke Meter . 502
Examine and Adjust Valve Clearance 504
How to Examine Valve Clearance 504
How to Adjust Valve Clearance . 505
Examine Compression Pressure 507
How to Examine Compression Pressure . 507
Examine Blowby Pressure . 512
How to Examine Blowby Pressure 512
Examine Engine Oil Pressure . 515
How to Examine Engine Oil Pressure 515
Visual Check Inside of EGR Valve 517
How to do the Visual Check Inside of EGR Valve 517
Clean Inside of EGR Valve . 519
How to Clean Inside of EGR Valve 519
Examine Fuel Pressure . 522
How to Examine Fuel Pressure 523
Examine Fuel Discharge, Return and Leakage 527
How to Examine Fuel Discharge, Return, and Leakage 528
Bleed Air from Fuel System 533
How to Bleed Air from Fuel System . 533
Examine Fuel Circuit for Leakage 535
How to Examine Fuel System for Leakage 535
Handle Cylinder Cut-out Mode Operation 537
Handle No-Injection Cranking Operation 538
Examine KDOC, SCR and Muffler Stack for Looseness and Damage 539
How to Examine KDOC, SCR and Muffler Stack for Looseness and Damage . 539
Examine Installed Condition of Cylinder Heads and Manifolds . 540
How to Examine Installed Condition of Cylinder Heads and Manifolds 540
Examine Engine Piping for Damage and Looseness 541
How to Examine Engine Piping for Damage and Looseness . 541
Examine and Adjust Air Conditioner Compressor Belt Tension 542
How to Examine Air Conditioner Compressor Belt 542
How to Adjust Air Conditioner Compressor Belt . 542
Examine Alternator Belt . 544
How to Examine Alternator Belt 544
Examine Automatic Tensioner . 546
How to Examine Automatic Tensioner 546
Examine SCR Related Functions . 549
Examine DEF Pump Raised Pressure 553
Examine Injection Volume from DEF Injector 556
Examine DEF Line Heater Relay 1 . 562
Examine DEF Line Heater Relay 2 . 566
Examine DEF Pump Heater Relay . 570
Examine DEF Tank Heater Valve . 574
Examine SCR Denitration Efficiency 578
Clean DEF Tank 581
How to Clean DEF Tank . 581
Clean DEF Pump 586
How to Clean DEF Pump . 586
Power Train . 592
Examine and Adjust HST Oil Pressure . 592
How to Examine HST Oil Pressure . 592
How to Adjust HST Oil Pressure 595
Examine the Control Pressure of Transfer Clutch . 597
How to Examine the Control Pressure of Transfer Clutch 597
Examine Drive Shaft for Looseness, Backlash, and Damage . 599
How to Examine Drive Shaft for Looseness, Backlash, and Damage 599
Steering System . 600
Examine Steering Wheel 600
How to Examine Steering Wheel . 600
Examine and Adjust Steering Circuit Oil Pressure 602
How to Examine Steering Circuit Oil Pressure 602
How to Adjust Steering Circuit Oil Pressure . 603
Bleed Air from Steering Cylinder Circuit 605
How to Bleed Air from Steering Cylinder Circuit . 605
Brake System 606
Release Remained Pressure in Brake Accumulator Circuit 606
How to Release Remained Pressure in Brake Accumulator Circuit . 606
Examine Wheel Brake Oil Pressure 607
How to Examine Wheel Brake Oil Pressure . 607
Examine and Adjust Brake Accumulator Charge Pressure 609
How to Examine Brake Accumulator Charge Pressure 609
How to Adjust Brake Accumulator Charge Pressure . 610
Bleed Air from Brake Circuit 611
How to Bleed Air from Brake Circuit . 611
Examine Brake Performance . 613
How to Examine Brake Performance 613
Examine Brake Pedal . 614
How to Examine Brake Pedal 614
Examine and Adjust Brake Pedal and Linkage 615
How to Examine Brake Pedal and Linkage 615
How to Adjust Brake Pedal and Linkage . 615
Examine Pressure Decrease of Wheel Brake 616
How to Examine Pressure Decrease of Wheel Brake . 617
Examine Wear of Wheel Brake Disc 619
How to Examine Wear of Wheel Brake Disc . 619
Examine Parking Brake Oil Pressure 621
How to Examine Parking Brake Oil Pressure . 621
Examine Parking Brake Performance . 623
How to Examine Parking Brake Performance 623
Release Parking Brake Manually 624
How to Release Parking Brake Manually . 624
Hydraulic System 625
Release Remained Pressure from Work Equipment Circuit . 625
How to Release Remained Pressure from Work Equipment Circuit 625
Examine and Adjust Work Equipment Oil Pressure 627
How to Examine Work Equipment Oil Pressure 627
How to Adjust Work Equipment Oil Pressure . 628
Examine Work Equipment PPC Oil Pressure . 630
How to Examine Work Equipment PPC Oil Pressure 630
Bleed Air from Work Equipment PPC Circuit . 632
How to Bleed Remaining Pressure from Work Equipment PPC Circuit . 632
Examine Cooling Fan Speed . 633
How to Examine Cooling Fan Speed 633
Examine Cooling Fan Circuit Oil Pressure 634
How to Examine Cooling Fan Circuit Oil Pressure . 634
Bleed Air from Cooling Fan Circuit 636
How to Bleed Air from Cooling Fan Circuit . 636
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas . 638
How to Examine ECSS Accumulator Nitrogen Gas Pressure . 638
How to Charge ECSS Accumulator with Nitrogen Gas 640
Work Equipment 643
Examine and Adjust Bucket Positioner 643
How to Examine Bucket Positioner 643
How to Adjust Bucket Positioner . 643
CAB Related Parts . 645
Examine Directional Lever . 645
How to Examine Directional Lever 645
Examine Multifunction Mono-Lever 646
How to Examine Multifunction Mono-Lever . 646
Examine Accelerator Pedal . 648
How to Examine Accelerator Pedal 648
Adjust Play of Operator Seat 650
How to Adjust Play of Operator Seat . 650
Electrical System . 651
Set and Adjust Each Equipment . 651
Set and Operate Machine Monitor . 653
Operator Mode . 657
Function to Show Technician Identification Status Screen 657
Function to Show Operator Identification Input Screen . 657
Examine Function by LCD (Liquid Crystal Display) 658
Examine Function of Service Meter and Odometer 659
How to Set Usage Limitation and Change Maintenance Password . 659
Service Mode 663
How to Operate Service Mode . 663
How to See Pre-defined Monitoring Information . 665
How to Examine Self-Define Monitor Information 671
Abnormality Record Menu . 683
How to See Maintenance Record . 688
Maintenance Mode Setting 690
How to Set Phone Number Entry . 695
Default Menu 697
Diagnostic Tests Menu . 711
Adjustment Menu . 721
No-Injection Cranking Operation . 740
KOMTRAX Settings Menu . 743
How to Show Service Message . 748
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 750
How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) . 754
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) . 756
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 762
Adjust Rearview Camera Angle 764
How to Adjust Rearview Camera Angle . 764
Set Region of Bluetooth(R) Compatible Radio . 766
How to Set Region of Bluetooth(R) Compatible Radio 766
Handle Voltage Circuit of Engine Controller . 768
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 769
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) . 770
Examine Diodes 771
How to Examine Diodes by Digital Tester . 771
How to Examine Diodes by Analog Tester 771
Pm Clinic . 772
Pm Clinic Service . 772
Pm Clinic Check Sheet: WA200-8 774
40 Troubleshooting 783
Table of Contents . 784
Precautions Before Work . 795
Abbreviation List . 796
Related Information to Troubleshooting 802
General Troubleshooting Points 802
Troubleshooting Points for Urea SCR System 803
Sequence of Events in Troubleshooting . 815
Checks Before Troubleshooting . 817
Inspection Procedure Before Troubleshooting . 819
Walk-Around Check . 819
Test in Accordance with Testing Procedure . 821
Examine Fuel Level and Type . 821
Examine for Impure Ingredient in Fuel . 821
Examine DEF Level and Type 822
Examine Fuel Prefilter 822
Examine Fuel Main Filter 824
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type . 826
Examine Coolant Level (Reservoir Tank) 827
Examine Air Cleaner Clogging 828
Clean Outer Element . 829
Replace Element . 831
Examine Hydraulic Oil Level . 833
Examine Hydraulic Oil Filter 835
Examine the Oil Level in the Transfer Case 836
Examine Oil Level in Front Axle Case 837
Examine Oil Level in Rear Axle Case . 838
Bleed Air from Fuel System 839
Bleed Air from Hydraulic System . 839
How to Examine Electric Equipment . 839
Preparation for Troubleshooting of Electrical System 846
Procedure for Troubleshooting . 855
Symptom and Troubleshooting Numbers . 857
Information Shown in Troubleshooting Table 861
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness . 863
Connector List and Layout (Machine with KOMTRAX Terminal) . 866
Connector List and Layout (Machine with Gateway Function Controller) 883
Connector Contact Connection Table 903
T-Branch Box and T-Branch Adapter Table . 944
Fuse Location Table (Machine with KOMTRAX Terminal) . 950
Fuse Location Table (Machine with Gateway Function Controller) 954
Precautions When You Replace KDOC . 958
Prepare Troubleshoot Machine Monitor 959
Procedure to Make Harness Checker on Machine Monitor LCD Unit . 961
Failure Code Table 967
Troubleshooting by Failure Code (Display of Code) . 986
Failure Code [2F00MA] . 986
Failure Code [2F00MB] . 989
Failure Code [2G42ZG] . 991
Failure Code [2G43ZG] . 993
Failure Code [6091NX] . 995
Failure Code [7RHYKA] . 997
Failure Code [7RHYKB] . 999
Failure Code [7RHYKY] .1001
Failure Code [879AKA] .1003
Failure Code [879AKB] .1005
Failure Code [879BKA] .1007
Failure Code [879BKB] .1009
Failure Code [879CKA] .1011
Failure Code [879CKB] .1013
Failure Code [879DKZ] .1015
Failure Code [879EMC] .1017
Failure Code [879FMC] .1018
Failure Code [989FN1] .1019
Failure Code [989L00] .1020
Failure Code [989M00] .1021
Failure Code [989N00] .1022
Failure Code [A1U0N3] .1023
Failure Code [A1U0N4] .1025
Failure Code [AB00KE] .1027
Failure Code [AB00KY] .1029
Failure Code [AQ10MB] .1031
Failure Code [AQ10N3] .1033
Failure Code [AS00R2] .1035
Failure Code [AS00R3] .1036
Failure Code [AS00R4] .1037
Failure Code [AS00R5] .1038
Failure Code [AS00R6] .1039
Failure Code [AS00ZK] .1040
Failure Code [AS10KM] .1041
Failure Code [AS10NR] .1042
Failure Code [AS10NT] .1043
Failure Code [B@BAZG] .1044
Failure Code [B@BCNS] .1045
Failure Code [B@BCZK] .1046
Failure Code [B@C6NS] .1048
Failure Code [B@CRNS] .1050
Failure Code [CA115] 1051
Failure Code [CA122] 1052
Failure Code [CA123] 1054
Failure Code [CA131] 1056
Failure Code [CA132] 1058
Failure Code [CA144] 1061
Failure Code [CA145] 1063
Failure Code [CA153] 1065
Failure Code [CA154] 1067
Failure Code [CA187] 1069
Failure Code [CA221] 1071
Failure Code [CA222] 1073
Failure Code [CA227] 1075
Failure Code [CA234] 1077
Failure Code [CA238] 1078
Failure Code [CA239] 1079
Failure Code [CA249] 1080
Failure Code [CA256] 1082
Failure Code [CA271] 1084
Failure Code [CA272] 1086
Failure Code [CA295] 1088
Failure Code [CA322] 1089
Failure Code [CA324] 1091
Failure Code [CA331] 1093
Failure Code [CA332] 1095
Failure Code [CA343] 1097
Failure Code [CA351] 1098
Failure Code [CA352] 1099
Failure Code [CA356] 1101
Failure Code [CA357] 1103
Failure Code [CA386] 1105
Failure Code [CA428] 1106
Failure Code [CA429] 1108
Failure Code [CA431] 1110
Failure Code [CA432] 1113
Failure Code [CA435] 1117
Failure Code [CA441] 1119
Failure Code [CA442] 1121
Failure Code [CA451] 1122
Failure Code [CA452] 1124
Failure Code [CA488] 1126
Failure Code [CA515] 1127
Failure Code [CA516] 1129
Failure Code [CA553] 1131
Failure Code [CA555] 1132
Failure Code [CA556] 1133
Failure Code [CA559] 1134
Failure Code [CA595] 1137
Failure Code [CA687] 1139
Failure Code [CA689] 1141
Failure Code [CA691] 1144
Failure Code [CA692] 1146
Failure Code [CA697] 1148
Failure Code [CA698] 1149
Failure Code [CA731] 1150
Failure Code [CA778] 1152
Failure Code [CA1117] .1156
Failure Code [CA1664] .1158
Failure Code [CA1669] .1160
Failure Code [CA1673] .1161
Failure Code [CA1677] .1162
Failure Code [CA1678] .1163
Failure Code [CA1682] .1164
Failure Code [CA1683] .1169
Failure Code [CA1684] .1171
Failure Code [CA1686] .1173
Failure Code [CA1691] .1174
Failure Code [CA1694] .1176
Failure Code [CA1695] .1178
Failure Code [CA1696] .1179
Failure Code [CA1712] .1182
Failure Code [CA1713] .1185
Failure Code [CA1714] .1187
Failure Code [CA1715] .1188
Failure Code [CA1776] .1189
Failure Code [CA1777] .1192
Failure Code [CA1843] .1195
Failure Code [CA1844] .1197
Failure Code [CA1885] .1200
Failure Code [CA1887] .1202
Failure Code [CA1896] .1204
Failure Code [CA1898] .1208
Failure Code [CA1938] .1210
Failure Code [CA1942] .1212
Failure Code [CA1961] .1213
Failure Code [CA1962] .1214
Failure Code [CA2185] .1215
Failure Code [CA2186] .1217
Failure Code [CA2198] .1219
Failure Code [CA2272] .1220
Failure Code [CA2288] .1222
Failure Code [CA2311] .1223
Failure Code [CA2349] .1224
Failure Code [CA2353] .1226
Failure Code [CA2357] .1228
Failure Code [CA2373] .1229
Failure Code [CA2374] .1231
Failure Code [CA2375] .1233
Failure Code [CA2376] .1235
Failure Code [CA2387] .1238
Failure Code [CA2554] .1239
Failure Code [CA2555] .1241
Failure Code [CA2556] .1243
Failure Code [CA2634] .1245
Failure Code [CA2635] .1247
Failure Code [CA2636] .1248
Failure Code [CA2637] .1250
Failure Code [CA2771] .1252
Failure Code [CA2961] .1256
Failure Code [CA2973] .1257
Failure Code [CA2976] .1258
Failure Code [CA3142] .1260
Failure Code [CA3143] .1261
Failure Code [CA3144] .1262
Failure Code [CA3146] .1265
Failure Code [CA3147] .1266
Failure Code [CA3148] .1267
Failure Code [CA3151] .1270
Failure Code [CA3165] .1278
Failure Code [CA3228] .1280
Failure Code [CA3229] .1282
Failure Code [CA3231] .1284
Failure Code [CA3232] .1286
Failure Code [CA3235] .1290
Failure Code [CA3239] .1292
Failure Code [CA3241] .1295
Failure Code [CA3242] .1298
Failure Code [CA3251] .1301
Failure Code [CA3313] .1303
Failure Code [CA3314] .1304
Failure Code [CA3315] .1305
Failure Code [CA3419] .1307
Failure Code [CA3421] .1309
Failure Code [CA3497] .1311
Failure Code [CA3498] .1312
Failure Code [CA3545] .1313
Failure Code [CA3547] .1315
Failure Code [CA3558] .1316
Failure Code [CA3559] .1318
Failure Code [CA3562] .1320
Failure Code [CA3563] .1322
Failure Code [CA3567] .1325
Failure Code [CA3568] .1329
Failure Code [CA3571] .1335
Failure Code [CA3572] .1337
Failure Code [CA3574] .1339
Failure Code [CA3575] .1342
Failure Code [CA3577] .1344
Failure Code [CA3578] .1346
Failure Code [CA3582] .1348
Failure Code [CA3583] .1355
Failure Code [CA3596] .1357
Failure Code [CA3649] .1361
Failure Code [CA3681] .1363
Failure Code [CA3682] .1368
Failure Code [CA3713] .1373
Failure Code [CA3717] .1376
Failure Code [CA3718] .1377
Failure Code [CA3724] .1378
Failure Code [CA3725] .1379
Failure Code [CA3741] .1382
Failure Code [CA3748] .1383
Failure Code [CA3755] .1385
Failure Code [CA3866] .1387
Failure Code [CA3868] .1390
Failure Code [CA4152] .1394
Failure Code [CA4155] .1398
Failure Code [CA4156] .1401
Failure Code [CA4157] .1404
Failure Code [CA4159] .1406
Failure Code [CA4164] .1407
Failure Code [CA4165] .1409
Failure Code [CA4166] .1411
Failure Code [CA4168] .1412
Failure Code [CA4169] .1415
Failure Code [CA4171] .1417
Failure Code [CA4249] .1419
Failure Code [CA4251] .1421
Failure Code [CA4261] .1423
Failure Code [CA4277] .1426
Failure Code [CA4459] .1430
Failure Code [CA4461] .1432
Failure Code [CA4533] .1435
Failure Code [CA4534] .1436
Failure Code [CA4731] .1437
Failure Code [CA4732] .1438
Failure Code [CA4739] .1439
Failure Code [CA4768] .1440
Failure Code [CA4769] .1442
Failure Code [CA4842] .1444
Failure Code [CA4952] (Machine with KOMTRAX Terminal) .1447
Failure Code [CA4952] (Machine with Gateway Function Controller) 1449
Failure Code [CA5115] .1451
Failure Code [CA5179] .1454
Failure Code [CA5181] .1456
Failure Code [CA5387] .1458
Failure Code [CA5388] .1460
Failure Code [CA5389] .1463
Failure Code [CA5391] .1465
Failure Code [CA5392] .1469
Failure Code [CA5393] .1471
Failure Code [CA5394] .1474
Failure Code [CA5395] .1477
Failure Code [CA5396] .1480
Failure Code [CA5631] .1481
Failure Code [CA5632] .1483
Failure Code [CA5938] .1484
Failure Code [D110L4] .1486
Failure Code [D160KA] .1488
Failure Code [D160KY] .1490
Failure Code [D191KA] .1491
Failure Code [D191KB] .1493
Failure Code [D191KY] .1495
Failure Code [D192KA] .1496
Failure Code [D192KB] .1497
Failure Code [D192KY] .1498
Failure Code [D19JKZ] .1499
Failure Code [D1B0KA] .1501
Failure Code [D1B0KB] .1503
Failure Code [D1B0KY] .1505
Failure Code [D1B0MC] .1507
Failure Code [D1E6KA] .1509
Failure Code [D1E6KB] .1511
Failure Code [D1E6KY] .1513
Failure Code [D5ZHKA] .1515
Failure Code [D5ZHKB] .1517
Failure Code [D5ZHL6] .1519
Failure Code [D811MC] (Machine with KOMTRAX Terminal) .1521
Failure Code [D811MC] (Machine with Gateway Function Controller) 1522
Failure Code [D862KA] (Machine with KOMTRAX Terminal) .1523
Failure Code [D862KA] (Machine with Gateway Function Controller) 1524
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) .1525
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1527
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) .1529
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1531
Failure Code [D8AQK4] (Machine with KOMTRAX Terminal) .1533
Failure Code [D8AQK4] (Machine with Gateway Function Controller) 1537
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) .1541
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 1545
Failure Code [D8G1KT] .1549
Failure Code [D8G6KT] .1550
Failure Code [DAF0KT] .1551
Failure Code [DAF0MB] .1552
Failure Code [DAF0MC] .1553
Failure Code [DAF3KK] .1554
Failure Code [DAF8KB] .1556
Failure Code [DAFDKB] .1558
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) .1560
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1561
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) .1562
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 1564
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) .1566
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 1568
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) .1570
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1575
Failure Code [DAJ0KK] .1580
Failure Code [DAJ0KT] .1583
Failure Code [DAJ0MC] .1584
Failure Code [DAJ1KA] .1585
Failure Code [DAJ2KK] .1587
Failure Code [DAJ4KB] .1590
Failure Code [DAJ4KZ] .1592
Failure Code [DAJ5KX] .1594
Failure Code [DAJ6KX] .1596
Failure Code [DAJ9KQ] .1598
Failure Code [DAJLKA] (Machine with KOMTRAX Terminal) .1599
Failure Code [DAJLKA] (Machine with Gateway Function Controller) 1601
Failure Code [DAJLKB] (Machine with KOMTRAX Terminal) .1603
Failure Code [DAJLKB] (Machine with Gateway Function Controller) 1605
Failure Code [DAJQKR] (Machine with KOMTRAX Terminal) .1607
Failure Code [DAJQKR] (Machine with Gateway Function Controller) 1612
Failure Code [DAJRKR] (Machine with KOMTRAX Terminal) .1617
Failure Code [DAJRKR] (Machine with Gateway Function Controller) 1622
Failure Code [DAJRMA] .1627
Failure Code [DAZ9KQ] .1628
Failure Code [DAZQKR] (Machine with KOMTRAX Terminal) .1629
Failure Code [DAZQKR] (Machine with Gateway Function Controller) 1633
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) .1637
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 1643
Failure Code [DB2RKR] (Machine with KOMTRAX Terminal) .1649
Failure Code [DB2RKR] (Machine with Gateway Function Controller) 1654
Failure Code [DDAAL6] .1659
Failure Code [DDB6L4] .1661
Failure Code [DDD7KA] .1663
Failure Code [DDD7KY] .1665
Failure Code [DDE5MA] .1667
Failure Code [DDE7KA] .1669
Failure Code [DDE7KB] .1671
Failure Code [DDK3KA] .1673
Failure Code [DDK3KB] .1676
Failure Code [DDK6KA] .1679
Failure Code [DDK6KB] .1682
Failure Code [DDNRLD] .1685
Failure Code [DDS5L6] .1687
Failure Code [DF10KA] .1689
Failure Code [DF10KB] .1692
Failure Code [DGH1KX] .1695
Failure Code [DGR2KB] .1697
Failure Code [DGR2KZ] .1699
Failure Code [DHH1KX] .1701
Failure Code [DHH1KY] .1703
Failure Code [DHTCL6] .1705
Failure Code [DJF1KA] .1707
Failure Code [DK55KA] .1708
Failure Code [DK55KY] .1711
Failure Code [DK55L5] .1714
Failure Code [DK5DKA] .1715
Failure Code [DK5DKY] .1718
Failure Code [DK5DL8] .1721
Failure Code [DK5EKA] .1725
Failure Code [DK5EKY] .1728
Failure Code [DLM3KA] .1731
Failure Code [DLM3LC] .1732
Failure Code [DLT3KX] .1734
Failure Code [DLT4KX] .1736
Failure Code [DLT4L0] .1738
Failure Code [DLT4LC] .1739
Failure Code [DPQ1KR] .1741
Failure Code [DPQ2KR] .1744
Failure Code [DPQ3KR] .1747
Failure Code [DSJ0KR] (Machine with KOMTRAX Terminal) .1751
Failure Code [DSJ0KR] (Machine with Gateway Function Controller) 1756
Failure Code [DT22KB] .1761
Failure Code [DV00KB] .1763
Failure Code [DW26KA] .1764
Failure Code [DW26KB] .1766
Failure Code [DW26KY] .1768
Failure Code [DW44KA] .1770
Failure Code [DW44KB] .1772
Failure Code [DW44KY] .1774
Failure Code [DWM1KA] .1775
Failure Code [DWM1KB] .1776
Failure Code [DWM1KY] .1778
Failure Code [DWN6KA] .1779
Failure Code [DWN6KB] .1781
Failure Code [DWN6KY] .1782
Failure Code [DWN7KA] .1783
Failure Code [DWN7KB] .1785
Failure Code [DWN7KY] .1786
Failure Code [DWN8KA] .1787
Failure Code [DWN8KB] .1789
Failure Code [DWN8KY] .1790
Failure Code [DWPBKA] .1791
Failure Code [DWPBKB] .1793
Failure Code [DWPBKY] .1795
Failure Code [DX19KA] .1797
Failure Code [DX19KB] .1800
Failure Code [DX19KY] .1802
Failure Code [DX20KA] .1804
Failure Code [DX20KB] .1806
Failure Code [DX20KY] .1808
Failure Code [DXH7KA] .1810
Failure Code [DXH7KB] .1812
Failure Code [DXH7KY] .1814
Failure Code [DXH8KA] .1816
Failure Code [DXH8KB] .1818
Failure Code [DXH8KY] .1820
Failure Code [DXHJKA] .1822
Failure Code [DXHJKB] .1824
Failure Code [DXHJKY] .1826
Failure Code [DXHKKA] .1828
Failure Code [DXHKKB] .1830
Failure Code [DXHKKY] .1832
Failure Code [F313KA] .1834
Failure Code [F313KB] .1836
Failure Code [F314KA] .1837
Failure Code [F314KB] .1839
Failure Code [F315KB] .1841
Failure Code [F315KY] .1843
Failure Code [F316KB] .1845
Failure Code [F316KY] .1847
Failure Code [F318KB] .1849
Failure Code [F318KY] .1851
Failure Code [F31AKB] .1852
Failure Code [F31AKY] .1854
Failure Code [F31BKB] .1856
Failure Code [F31BKY] .1858
Failure Code [F31CKB] .1860
Failure Code [F31CKY] .1862
Failure Code [F31DKB] .1864
Failure Code [F31DKY] .1866
Failure Code [F31EKB] .1868
Failure Code [F31EKY] .1870
Failure Code [FS10ZE] .1872
Failure Code [H2K0KA] .1873
Failure Code [H2K0KY] .1875
Failure Code [J141N1] .1877
Failure Code [LA00L3] .1878
Failure Code [M100N1] .1879
Failure Code [M400N1] .1880
Troubleshooting of Electrical System (E-Mode) .1881
Engine Does Not Start (Engine Does Not Crank) .1881
Manual Preheating System Does Not Operate .1887
Automatic Preheating System Does Not Operate 1890
While Preheating is in Operation, Preheating Monitor Does Not Come On .1893
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing 1895
LCD Unit on Machine Monitor Shows Nothing .1898
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) .1900
LCD Screen on Machine Monitor Does Not Show Correctly .1902
Meter Unit Display on Machine Monitor is Abnormal .1904
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal 1907
LED Unit Lamp on Machine Monitor is Abnormal 1910
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly .1912
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 1915
Switch Panel Buzzer of Machine Monitor is Abnormal 1918
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally 1921
DEF Level is Not Shown Correctly 1922
Rearview Monitor Does Not Come On or Backlight Flickers .1925
Rearview Monitor Images are Not Shown Clearly .1928
Rearview Monitor Brightness Cannot be Adjusted 1933
Night Mode Lamp of Rearview Monitor is Abnormal .1937
Radiator Coolant Level Caution Lamp Does Not Come On 1939
Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position 1940
Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low .1944
Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low 1945
Indication of HST Oil Temperature Gauge Does Not Increase, or HST Oil Temperature Caution Lamp Does Not Come On .1946
Fuel Gauge Does Not Show Normally .1947
Seatbelt Caution Lamp Does Not Show Normally 1949
Alarm Buzzer Does Not Operate .1950
Alarm Buzzer Does Not Stop 1951
When the Secondary HST Travel Switch is Operated, It Does Not Work or When the Secondary HST Travel Switch is Not Operated, It Works 1952
Setting Does Not Change While You Operate the Traction Control Switch .1954
The Bucket Positioner Does Not Work or Cannot be Released .1956
The Boom Kick-out Does Not Work or Cannot be Released .1959
Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in Forward or Reverse Travel When Parking Brake is Released 1961
Directional Selector (FNR) Switch Mode is Not Selected or Not Released 1964
Traction Level Does Not Show MAX When Max. Traction Switch is Turned on .1966
ECSS Function Cannot be Selected or Cannot be Released 1968
Horn Does Not Sound .1970
Horn Does Not Stop 1973
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On 1975
Clearance Lamp and Tail Lamp Do Not Come On or Go Out .1977
High and Low Beams of Headlamp Do Not Come On or Go Out .1981
Low Beam of Headlamp Does Not Come On or Go Out .1985
High Beam of Headlamp Does Not Come On or Go Out 1987
Front Working Lamp Does Not Come On or Go Out .1989
Rear Working Lamp Does Not Come On or Go Out 1994
Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out .1998
Turn Signal Lamp Does Not Come On or Go Out .2001
Hazard Lamp Does Not Come On or Go Out 2004
Brake Lamp Does Not Come On or Stays Lit 2008
Backup Lamp Does Not Come On or Stays Lit .2012
Backup Buzzer Does Not Sound or Continues to Sound 2016
Front Wiper Does Not Operate 2018
Rear Wiper Does Not Operate .2022
Window Washer Does Not Operate 2025
KOMTRAX System Does Not Operate Correctly .2028
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .2029
Information Shown in Troubleshooting Table (H-Mode) .2029
Failure Mode and Cause Table 2030
Machine Can Not Move Forward or Reverse .2043
Machine Can Not Travel FORWARD (Machine Travels REVERSE Normally) .2045
Machine Can Not Travel REVERSE (Machine Travels FORWARD Normally) .2046
Travel Speed of FORWARD Travel and REVERSE Travel is Slow, or Power is Low 2047
Forward Travel Speed is Slow or Power is Low (Machine Travels REVERSE Normally) .2050
REVERSE Travel Speed is Slow or Power is Low (Machine Travels FORWARD Normally) .2052
Engine Speed Drops Largely or Engine Stops 2053
Machine Does Not Turn .2055
Steering Wheel is Heavy to Operate 2056
Machine Sways or Large Shocks are Made While Machine Turns 2057
Machine Unintentionally Turns to One Side When Machine Travels 2058
Wheel Brakes Do Not Operate or are Weak .2059
Wheel Brakes are Not Released or Drag .2061
Parking Brake Does Not Operate or is Weak .2062
Parking Brake is Not Released or Drags 2063
Boom Does Not Rise 2065
Boom Moves Slow or Lacks Lifting Force 2067
Rising Boom Slows Down at Specified Height 2069
Lift Cylinders Can Not Hold Bucket on Ground 2070
Hydraulic Drift of Boom is Large 2072
Boom Moves Up and Down During Operation .2073
Bucket Does Not Tilt Back .2074
Bucket Moves Slow or Lacks Tilt-Back Force 2076
Bucket Slows Down During Tilt Back Operation 2078
Bucket Cylinder Does Not Hold Bucket on Ground 2079
Hydraulic Drift of Bucket is Large 2081
Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold) .2082
Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move .2083
Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment 2084
Large Shocks are Made When Work Equipment Starts to Move and Stops 2085
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2087
ECSS Does Not Operate and Machine Pitches and Bounces .2088
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2089
Unusual Noise is Heard from Around Fan 2091
Troubleshooting of Engine (S-Mode) 2092
Information Shown in Troubleshooting Table (S-Mode) .2092
Engine Does Not Crank When Starting Switch is Turned to Start Position 2093
Engine Cranks but No Exhaust Smoke Comes Out 2094
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2095
Engine Startability is Unsatisfactory .2097
Engine Does Not Pick Up Smoothly 2099
Engine Stops During Operation .2101
Engine Does Not Rotate Smoothly .2103
Engine Lacks Output (or Lacks Power) 2104
Exhaust Smoke is Black 2106
Engine Oil Consumption is Excessive .2108
Engine Oil Becomes Dirty Quickly 2109
Fuel Consumption is Excessive .2110
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) .2111
Engine Oil Pressure Drops .2112
Fuel Mixes Into Engine Oil 2114
Water Mixes Into Engine Oil (Milky) .2115
Coolant Temperature Increases Too High (Overheat) .2116
Unusual Noise is Heard 2117
Vibration is Excessive 2118
Air Cannot be Bled from Fuel Circuit 2119
Active Regeneration is Done Frequently 2120
Active Regeneration Continues Long 2121
White Smoke is Exhausted During Active Regeneration .2122
DEF Consumption is Excessive 2123
There is an Unusual Smell (Irritating Odor) .2125
Foreign Materials Enter DEF (DEF Increases) .2126
50 Disassembly and Assembly .2127
Table of Contents .2128
Precautions Before Work .2132
Abbreviation List .2133
Related Information on Disassembly and Assembly .2139
How to Read This Manual .2139
Coating Materials List 2140
Special Tool List .2145
Sketches of Special Tools .2166
Engine and Cooling System .2178
Remove and Install Supply Pump Assembly .2178
How to Remove Supply Pump Assembly 2179
How to Install Supply Pump Assembly .2185
Remove and Install Injector Assembly 2191
How to Remove Injector Assembly .2191
How to Install Injector Assembly 2202
Remove and Install Cylinder Head Assembly .2214
How to Remove Cylinder Head Assembly 2215
How to Install Cylinder Head Assembly .2234
Remove and Install EGR Valve Assembly .2261
How to Remove EGR Valve Assembly 2261
How to Install EGR Valve Assembly .2264
Remove and Install EGR Cooler Assembly 2268
How to Remove EGR Cooler Assembly .2268
How to Install EGR Cooler Assembly 2275
Remove and Install Starter Assembly .2283
How to Remove Starting Motor Assembly .2283
How to Install Starting Motor Assembly 2285
Remove and Install Air Conditioner Compressor Belt 2287
How to Remove Air Conditioner Compressor Belt .2287
How to Install Air Conditioner Compressor Belt 2289
Remove and Install Alternator Belt 2291
How to Remove Alternator Belt .2291
How to Install Alternator Belt 2296
Remove and Install Alternator Assembly 2300
How to Remove Alternator Assembly .2300
How to Install Alternator Assembly 2302
Remove and Install Automatic Tensioner 2304
How to Remove Automatic Tensioner .2304
How to Install Automatic Tensioner 2309
Remove and Install Radiator Assembly 2314
How to Remove Radiator Assembly .2314
How to Install Radiator Assembly 2321
Remove and Install Cooling Fan and Fan Motor Assembly .2328
How to Remove Cooling Fan and Fan Motor Assembly 2328
How to Install Cooling Fan and Fan Motor Assembly .2332
Remove and Install Hydraulic Oil Cooler Assembly 2337
How to Remove Hydraulic Oil Cooler Assembly .2337
How to Install Hydraulic Oil Cooler Assembly 2340
Remove and Install Aftercooler Assembly .2342
How to Remove Aftercooler Assembly 2342
How to Install Aftercooler Assembly .2344
Remove and Install Engine Assembly 2347
How to Remove Engine Assembly .2348
How to Install Engine Assembly 2366
Remove and Install Engine Front Oil Seal 2386
How to Remove Engine Front Oil Seal .2386
How to Install Engine Front Oil Seal 2391
Remove and Install Engine Rear Oil Seal .2398
How to Remove Engine Rear Oil Seal 2399
How to Install Engine Rear Oil Seal .2401
Remove and Install Engine Hood Assembly .2405
How to Remove Engine Hood Assembly 2405
How to Install Engine Hood Assembly .2417
Remove and Install KDOC Assembly 2429
How to Remove KDOC Assembly .2429
How to Install KDOC Assembly 2436
Remove and Install KDOC and SCR Assembly 2446
How to Remove KDOC and SCR Assembly .2447
How to Install KDOC and SCR Assembly 2460
Remove and Install Bellows Pipe Assembly 2471
How to Remove Bellows Pipe Assembly .2471
How to Install Bellows Pipe Assembly 2475
Remove and Install Fuel Tank Assembly .2481
How to Remove Fuel Tank Assembly 2481
How to Install Fuel Tank Assembly .2485
Remove and Install DEF Tank Assembly 2490
How to Remove DEF Tank Assembly .2491
How to Install DEF Tank Assembly 2498
Remove and Install DEF Tank Sensor Flange Assembly 2506
How to Remove DEF Tank Sensor Flange Assembly .2506
How to Install DEF Tank Sensor Flange Assembly 2508
Remove and Install DEF Tank Sensor 2511
How to Remove DEF Tank Sensor .2511
How to Install DEF Tank Sensor 2512
Remove and Install DEF Tank Strainer 2519
How to Remove DEF Tank Strainer .2519
How to Install DEF Tank Strainer 2520
Remove and Install SCR Assembly .2521
How to Remove SCR Assembly 2521
How to Install SCR Assembly .2530
Remove and Install KCCV Assembly 2542
How to Remove KCCV Assembly .2542
How to Install KCCV Assembly 2544
Remove and Install VGT Assembly .2546
How to Remove VGT Assembly 2546
How to Install VGT Assembly .2561
Remove and Install DEF Mixing Tube 2577
How to Remove DEF Mixing Tube .2577
How to Install DEF Mixing Tube 2583
Remove and Install DEF Injector .2590
How to Remove DEF Injector 2590
How to Install DEF Injector .2593
Remove and Install DEF Pump .2596
How to Remove DEF Pump 2596
How to Install DEF Pump .2600
Remove and Install DEF Hose .2605
How to Remove DEF Hose 2605
How to Install DEF Hose .2615
Remove and Install Air Cleaner Assembly .2626
How to Remove Air Cleaner Assembly 2626
How to Install Air Cleaner Assembly .2630
Remove and Install Air Conditioner Compressor Assembly 2634
How to Remove Air Conditioner Compressor Assembly .2635
How to Install Air Conditioner Compressor Assembly 2638
Remove and Install Air Conditioner Condenser Assembly .2641
How to Remove Air Conditioner Condenser Assembly 2641
How to Install Air Conditioner Condenser Assembly .2643
Power Train .2645
Remove and Install HST Pump Assembly, Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump Assembly .2645
How to Remove HST Pump Assembly, Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump Assembly 2646
How to Install HST Pump Assembly, Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump Assembly .2650
Remove and Install HST Motor 1 Assembly .2655
How to Remove HST Motor 1 Assembly 2655
How to Install HST Motor 1 Assembly .2658
Remove and Install HST Motor 2 Assembly .2660
How to Remove HST Motor 2 Assembly 2660
How to Install HST Motor 2 Assembly .2662
Remove and Install Transfer Assembly 2664
How to Remove Transfer Assembly .2665
How to Install Transfer Assembly 2672
Disassemble and Assemble Transfer Assembly 2680
How to Disassemble Transfer Assembly 2681
How to Assemble Transfer Assembly .2696
Remove and Install Parking Brake Assembly .2715
How to Remove Parking Brake Assembly 2715
How to Install Parking Brake Assembly .2717
Remove and Install Parking Brake Cylinder Assembly 2719
How to Remove Parking Brake Cylinder Assembly .2719
How to Install Parking Brake Cylinder Assembly 2720
Disassemble and Assemble Parking Brake Assembly .2722
How to Disassemble Parking Brake Assembly .2722
How to Assemble Parking Brake Assembly 2725
Remove and Install Front Axle Assembly 2730
How to Remove Front Axle Assembly .2730
How to Install Front Axle Assembly 2732
Remove and Install Rear Axle Assembly .2734
How to Remove Rear Axle Assembly 2734
How to Install Rear Axle Assembly .2736
Disassemble and Assemble Axle Housing Assembly 2739
How to Disassemble Axle Housing Assembly 2740
How to Assemble Axle Housing Assembly .2744
Disassemble and Assemble Differential Assembly 2752
How to Disassemble Differential Assembly 2753
How to Assemble Differential Assembly .2767
Undercarriage and Frame .2789
Remove and Install Center Hinge Pin .2789
How to Remove Center Hinge Pin 2790
How to Install Center Hinge Pin .2798
Remove and Install Counterweight Assembly .2810
How to Remove Counterweight Assembly 2810
How to Install Counterweight Assembly .2824
Hydraulic System 2835
Remove and Install Hydraulic Tank Assembly 2835
How to Remove Hydraulic Tank Assembly .2836
How to Install Hydraulic Tank Assembly 2842
Remove and Install Control Valve Assembly .2848
How to Remove Control Valve Assembly 2848
How to Install Control Valve Assembly .2853
Disassemble and Assemble Hydraulic Cylinder Assembly 2858
How to Disassemble Hydraulic Cylinder Assembly 2859
How to Assemble Hydraulic Cylinder Assembly .2862
Work Equipment 2869
Remove and Install Work Equipment Assembly 2869
How to Remove Work Equipment Assembly .2870
How to Install Work Equipment Assembly 2874
CAB Related Parts .2885
Remove and Install Operator Cab Assembly 2885
How to Remove Operator Cab Assembly .2886
How to Install Operator Cab Assembly 2898
Remove and Install Operator Cab Glass (Adhered Glass) .2911
How to Remove Operator Cab Glass (Adhered Glass) 2911
How to Install Operator Cab Glass (Adhered Glass) .2912
Remove and Install Air Conditioner Unit Assembly 2921
How to Remove Air Conditioner Unit Assembly .2921
How to Install Air Conditioner Unit Assembly 2927
Remove and Install Operator Seat Assembly .2934
How to Remove Operator Seat Assembly 2934
How to Install Operator Seat Assembly .2934
How to Remove and Install Seat Belt .2936
How to Remove Seat Belt .2936
How to Install Seatbelt .2936
Electrical System .2938
Remove and Install Engine Controller Assembly .2938
How to Remove Engine Controller Assembly 2938
How to Install Engine Controller Assembly .2942
Remove and Install HST Controller Assembly 2947
How to Remove HST Controller Assembly .2947
How to Install HST Controller Assembly 2949
Remove and Install Air Conditioner Controller Assembly 2951
How to Remove Air Conditioner Controller Assembly .2951
How to Install Air Conditioner Controller Assembly 2952
Remove and Install Monitor Controller Assembly 2954
How to Remove Monitor Controller Assembly .2954
How to Install Monitor Controller Assembly 2957
Remove and Install Machine Monitor Assembly .2959
How to Remove Machine Monitor Assembly 2959
How to Install Machine Monitor Assembly .2962
Remove and Install Mass Air Flow and Temperature Sensor .2965
How to Remove Mass Air Flow and Temperature Sensor 2965
How to Install Mass Air Flow and Temperature Sensor .2966
Remove and Install KCCV Crankcase Pressure Sensor .2968
How to Remove KCCV Crankcase Pressure Sensor 2968
How to Install KCCV Crankcase Pressure Sensor .2969
Remove and Install SCR Temperature Sensor .2971
How to Remove SCR Temperature Sensor 2971
How to Install SCR Temperature Sensor .2974
Remove and Install SCR Outlet NOx Sensor 2978
How to Remove SCR Outlet NOx Sensor .2978
How to Install SCR Outlet NOx Sensor 2981
Remove and Install KOMTRAX Terminal Assembly 2985
How to Remove KOMTRAX Terminal Assembly .2985
How to Install KOMTRAX Terminal Assembly 2986
Remove and Install Gateway Function Controller Assembly .2987
How to Remove Gateway Function Controller Assembly 2987
How to Install Gateway Function Controller Assembly .2988
Remove and Install Communication Terminal .2989
How to Remove Communication Terminal 2989
How to Install Communication Terminal .2991
60 Maintenance Standard .2995
Table of Contents .2996
Abbreviation List .2997
Engine and Cooling System .3003
Maintenance Standard for Engine Mount .3003
Maintenance Standard for Damper .3004
Maintenance Standard for Cooling Fan Motor 3005
Power Train .3009
Maintenance Standard for Drive Shaft 3009
Maintenance Standard for Transfer .3010
Maintenance Standard for Transfer Mount .3019
Maintenance Standard for Front Axle .3020
Maintenance Standard for Rear Axle 3021
Maintenance Standard for Front Torque Proportioning Differential 3022
Maintenance Standard for Rear Torque Proportioning Differential .3024
Maintenance Standard for Limited Slip Differential 3026
Maintenance Standard for Front Final Drive 3028
Maintenance Standard for Rear Final Drive .3030
Steering System .3032
Maintenance Standard for Steering Column 3032
Maintenance Standard for Priority Valve .3033
Maintenance Standard for Steering Cylinder 3034
Maintenance Standard for Secondary Steering Valve .3036
Brake System 3037
Maintenance Standard for Brake Circuit Accumulator Charge Valve .3037
Maintenance Standard for Slack Adjuster .3038
Maintenance Standard for Front Brake 3039
Maintenance Standard for Rear Brake .3040
Maintenance Standard for Parking Brake 3041
Undercarriage and Frame .3042
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin .3042
Hydraulic System 3047
Maintenance Standard for Hydraulic Tank .3047
Maintenance Standard for Steering, Work Equipment, Brake and Cooling Fan, and Transfer Lubrication Pump .3048
Maintenance Standard for Control Valve 3050
Maintenance Standard for Multifunction Mono-Lever PPC Valve .3053
Maintenance Standard for Attachment EPC Solenoid Valve 3055
Work Equipment 3056
Maintenance Standard for Work Equipment Linkage .3056
Maintenance Standard for Bucket .3059
Maintenance Standard for Lift Cylinder 3060
Maintenance Standard for Bucket Cylinder 3061
Maintenance Standard for Coupler Plunger 3062
CAB Related Parts .3063
Maintenance Standard for CAB Mount 3063
80 Appendix .3065
Table of Contents .3066
Precautions Before Work .3068
Abbreviation List .3069
Air Conditioner System 3075
Precautions for Refrigerant .3075
Air Conditioner Component .3076
Specifications of Air Conditioner .3078
Structure and Function of Refrigeration Cycle .3079
Outline of Refrigeration Cycle 3080
Component Parts of Air Conditioner System .3082
Air Conditioner Unit 3082
Configuration Diagram of Air Conditioner Unit .3082
Function of Air Conditioner Unit 3083
Component Parts of Air Conditioner Unit .3084
Function of Evaporator as Air Conditioner Unit Component 3084
Function of Inside Air Temperature Sensor as Air Conditioner Unit Component .3084
Function of Blower Amplifier as Air Conditioner Unit Component 3085
Function of Blower OFF Relay as Air Conditioner Unit Component 3085
Function of Compressor Clutch Relay as Air Conditioner Unit Component .3085
Function of Heater Core as Air Conditioner Unit Component .3085
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .3085
Function of Servo Motor as Air Conditioner Unit Component .3085
Function of Expansion Valve as Air Conditioner Unit Component .3086
Function of Dual Pressure Switch 3086
Air Conditioner Controller 3087
Structure of Air Conditioner Controller .3087
Compressor 3088
Structure of Compressor .3088
Specifications of Compressor 3088
Function of Compressor 3088
Condenser .3089
Structure of Condenser 3089
Specifications of Condenser .3089
Function of Condenser .3089
Receiver Drier 3090
Structure of Receiver Dryer .3090
Specifications of Receiver Dryer 3090
Function of Receiver Dryer 3090
Air Conditioner Related Sensors .3091
Function of Sunlight Sensor .3091
Function of Outside Air Temperature Sensor 3091
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .3092
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3094
System Diagram of Air Conditioner .3097
Input and Output Signals of Air Conditioner Controller 3098
Function of Air Conditioner Controller 3099
Locations of Air Conditioner Parts and Layout of Connectors .3100
Examine Air Conditioner with Self-Diagnosis Function 3106
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .3107
Examine Temperature Control Function 3108
How to Examine Temperature Control Function .3108
Examine Vent (Mode) Changeover 3110
How to Examine Vent (Mode) Changeover .3110
Examine Fresh/Recirc Air Changeover .3112
How to Examine Fresh/Recirc Air Changeover 3112
Examine Evaporator Temperature Sensor .3114
Examine Relay .3116
How to Examine Relay 3116
Air Conditioner Troubleshooting Chart 1 .3118
Air Conditioner Troubleshooting Chart 2 .3119
Failure Code [879AKA] .3122
Failure Code [879AKB] .3124
Failure Code [879BKA] .3126
Failure Code [879BKB] .3128
Failure Code [879CKA] .3130
Failure Code [879CKB] .3132
Failure Code [879DKZ] .3134
Failure Code [879EMC] .3136
Failure Code [879FMC] .3137
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3138
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .3141
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3144
Troubleshooting for Fresh/Recirc Air Changeover .3148
Troubleshooting by Gauge Pressure .3150
Connect Service Tool 3153
How to Connect Service Tool .3154
Precautions for Disconnection and Connection of Air Conditioner Piping 3155
Handle Compressor Oil .3157
90 Circuit Diagrams .3159
Table of Contents .3160
Abbreviation List .3161
Hydraulic Circuit Diagram .3167
Symbols Used in Hydraulic Circuit Diagram .3167
Hydraulic Circuit Diagram .3171
Electrical Circuit Diagram 3173
Symbols Used in Electric Circuit Diagram 3173
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (1/10) 3177
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (2/10) 3179
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (3/10) 3181
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (4/10) 3183
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (5/10) 3185
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (6/10) 3187
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (7/10) 3189
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (8/10) 3191
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (9/10) 3193
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (10/10) .3195
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (1/13) .3197
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (2/13) .3199
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (3/13) .3201
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (4/13) .3203
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (5/13) .3205
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (6/13) .3207
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (7/13) .3209
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (8/13) .3211
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (9/13) .3213
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (10/13) 3215
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (11/13) 3217
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (12/13) 3219
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (13/13) 3221
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (1/9) .3223
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (2/9) .3225
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (3/9) .3227
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (4/9) .3229
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (5/9) .3231
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (6/9) .3233
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (7/9) .3235
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (8/9) .3237
Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (9/9) .3239
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (1/10) .3241
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (2/10) .3243
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (3/10) .3245
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (4/10) .3247
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (5/10) .3249
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (6/10) .3251
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (7/10) .3253
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (8/10) .3255
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (9/10) .3257
Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (10/10) 3259
Index 3261

DESCRIPTION:

Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-11 –  PDF DOWNLOAD

• SERIAL NUMBERS 85001 and up

G.B 28/12/24