Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-07 – PDF DOWNLOAD

Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-07 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-07 – PDF DOWNLOAD

Language : English
Pages : 3044
Downloadable : Yes
File Type : PDF
Size: 72.1 MB

DESCRIPTION:

Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-07 – PDF DOWNLOAD

SERIAL NUMBERS 85001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

General precautions
If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation
and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.
• Always wear the protective eyeglasses when hitting parts
with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, always
agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang “UNDER REPAIR” warning tag in the operator’s
compartment Before starting work.
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work:
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible,
insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang “UNDER REPAIR” warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately.

TABLE OF CONTENTS:

Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-07 – PDF DOWNLOAD

INDEX
00 INDEX AND FOREWORD 00-1
ABBREVIATION LIST 00-19
FOREWORD, SAFETY, BASIC INFORMATION 00-25
HOW TO READ THE SHOP MANUAL 00-25
SAFETY NOTICE FOR OPERATION 00-27
PRECAUTIONS TO PREVENT FIRE 00-35
ACTIONS IF FIRE OCCURS 00-37
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00-38
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 00-39
PRECAUTIONS FOR DEF 00-40
STORE AdBlue/DEF 00-41
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00-42
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 00-45
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00-52
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00-54
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00-55
PRACTICAL USE OF KOMTRAX 00-56
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00-57
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00-61
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00-65
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00-66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00-68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00-69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
00-71
HOW TO READ ELECTRICAL WIRE CODE 00-72
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00-76
STANDARD TIGHTENING TORQUE TABLE 00-79
CONVERSION TABLE 00-86
01 SPECIFICATIONS 01-1
CONTENTS 01-2
ABBREVIATION LIST 01-3
SPECIFICATIONS 01-9
SPECIFICATION DRAWING 01-9
SPECIFICATIONS 01-11
WEIGHT TABLE 01-17
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 01-19
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 01-21
10 STRUCTURE AND FUNCTION 10-1
CONTENTS 10-2
ABBREVIATION LIST 10-6
UREA SCR SYSTEM 10-12
LAYOUT DRAWING OF UREA SCR SYSTEM 10-12
UREA SCR SYSTEM DIAGRAM 10-14
FUNCTION OF UREA SCR SYSTEM 10-15
COMPONENT PARTS OF UREA SCR SYSTEM 10-32
BOOT-UP SYSTEM 10-41
LAYOUT DRAWING OF BOOT-UP SYSTEM 10-41
SYSTEM OPERATING LAMP SYSTEM 10-43
BATTERY DISCONNECT SWITCH 10-44
PREHEATING SYSTEM 10-45
ENGINE SYSTEM 10-47
LAYOUT DRAWING OF ENGINE SYSTEM 10-47
ENGINE CONTROL SYSTEM 10-49
AUTOMATIC IDLE STOP SYSTEM 10-56
COMPONENT PARTS OF ENGINE SYSTEM 10-57
INDEX 00 INDEX AND FOREWORD
00-2 WA200-8
COOLING SYSTEM 10-74
LAYOUT DRAWING OF COOLING SYSTEM 10-74
COOLING FAN CONTROL SYSTEM 10-76
COMPONENT PARTS OF COOLING SYSTEM 10-81
CONTROL SYSTEM 10-92
LAYOUT DRAWING OF CONTROL SYSTEM 10-92
MACHINE MONITOR SYSTEM 10-94
REARVIEW MONITOR SYSTEM 10-96
KOMTRAX SYSTEM 10-97
COMPONENT PARTS OF CONTROL SYSTEM 10-98
HYDRAULIC SYSTEM 10-141
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10-141
COMPONENT PARTS OF HYDRAULIC SYSTEM 10-142
POWER TRAIN SYSTEM 10-168
LAYOUT DRAWING OF POWER TRAIN SYSTEM 10-168
OPERATION OF POWER TRAIN SYSTEM 10-170
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 10-171
HST CONTROL SYSTEM 10-173
HST CHARGE SYSTEM 10-175
HST PUMP CONTROL SYSTEM 10-176
HST CONTROLLER GEAR SHIFT CONTROL FUNCTION 10-178
TRANSFER CLUTCH CONTROL FUNCTION 10-181
HST SYSTEM PROTECTION FUNCTION 10-182
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 10-184
COMPONENT PARTS OF POWER TRAIN SYSTEM 10-188
WORK EQUIPMENT SYSTEM 10-233
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10-233
WORK EQUIPMENT CONTROL SYSTEM 10-235
WORK EQUIPMENT LOCK SYSTEM 10-236
BUCKET POSITIONER SYSTEM 10-238
BOOM KICK-OUT SYSTEM 10-241
ECSS 10-244
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10-246
STEERING SYSTEM 10-258
LAYOUT DRAWING OF STEERING SYSTEM 10-258
STEERING COLUMN 10-259
COMPONENT PARTS OF STEERING SYSTEM 10-260
BRAKE SYSTEM 10-276
LAYOUT DRAWING OF BRAKE SYSTEM 10-276
PARKING BRAKE CONTROL SYSTEM 10-278
COMPONENT PARTS OF BRAKE SYSTEM 10-281
UNDERCARRIAGE AND FRAME 10-301
FRAME, AXLE MOUNT AND CENTER HINGE PIN 10-301
TIRE 10-304
WORK EQUIPMENT 10-306
STRUCTURE OF WORK EQUIPMENT 10-306
STRUCTURE OF BUCKET 10-307
CAB AND ITS ATTACHMENTS 10-308
ROPS CAB 10-308
CAB MOUNT 10-309
20 STANDARD VALUE TABLE 20-1
CONTENTS 20-2
ABBREVIATION LIST 20-3
STANDARD VALUE TABLE FOR ENGINE 20-9
STANDARD VALUE TABLE FOR ENGINE: WA200-8 20-9
STANDARD VALUE TABLE FOR MACHINE 20-14
STANDARD VALUE TABLE FOR MACHINE: WA200-8 20-14
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 20-26
00 INDEX AND FOREWORD INDEX
WA200-8 00-3
30 TESTING AND ADJUSTING 30-1
CONTENTS 30-2
ABBREVIATION LIST 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING 30-11
TOOLS FOR TESTING AND ADJUSTING 30-11
ENGINE AND COOLING SYSTEM 30-19
TEST ENGINE SPEED 30-19
TEST BOOST PRESSURE 30-23
TEST EXHAUST GAS COLOR 30-26
TEST AND ADJUST VALVE CLEARANCE 30-29
TEST COMPRESSION PRESSURE 30-32
TEST BLOWBY PRESSURE 30-37
TEST ENGINE OIL PRESSURE 30-40
TEST FUEL PRESSURE 30-42
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 30-47
BLEED AIR FROM FUEL SYSTEM 30-53
TEST FUEL CIRCUIT FOR LEAKAGE 30-55
HANDLE CYLINDER CUT-OUT MODE OPERATION 30-57
HANDLE NO-INJECTION CRANKING OPERATION 30-58
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 30-59
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 30-60
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 30-61
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 30-62
TEST ALTERNATOR BELT 30-64
TEST AUTOMATIC TENSIONER 30-66
TEST SCR RELATED FUNCTIONS 30-69
CLEAN AdBlue/DEF TANK 30-101
CLEAN AdBlue/DEF PUMP 30-106
POWER TRAIN 30-112
TEST AND ADJUST HST OIL PRESSURE 30-112
TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH 30-117
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 30-119
STEERING SYSTEM 30-120
TEST STEERING WHEEL 30-120
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 30-122
BLEED AIR FROM STEERING CYLINDER CIRCUIT 30-125
BRAKE SYSTEM 30-126
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 30-126
TEST WHEEL BRAKE OIL PRESSURE 30-127
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 30-129
BLEED AIR FROM BRAKE CIRCUIT 30-131
TEST BRAKING PERFORMANCE 30-133
TEST BRAKE PEDAL 30-134
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 30-135
TEST LOWERING OF WHEEL BRAKE PRESSURE 30-136
TEST WEAR OF WHEEL BRAKE DISC 30-139
TEST PARKING BRAKE OIL PRESSURE 30-141
TEST PARKING BRAKE PERFORMANCE 30-143
RELEASE PARKING BRAKE MANUALLY 30-144
HYDRAULIC SYSTEM 30-145
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 30-145
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 30-147
TEST WORK EQUIPMENT PPC OIL PRESSURE 30-150
BLEED AIR FROM WORK EQUIPMENT PPC CIRCUIT 30-152
TEST COOLING FAN SPEED 30-153
TEST COOLING FAN CIRCUIT OIL PRESSURE 30-154
BLEED AIR FROM COOLING FAN CIRCUIT 30-156
INDEX 00 INDEX AND FOREWORD
00-4 WA200-8
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH
NITROGEN GAS 30-158
WORK EQUIPMENT 30-163
TEST AND ADJUST BUCKET POSITIONER 30-163
CAB AND ITS ATTACHMENTS 30-165
TEST DIRECTIONAL LEVER 30-165
TEST MULTIFUNCTION MONO-LEVER 30-166
TEST ACCELERATOR PEDAL 30-168
ADJUST RATTLING OPERATOR’S SEAT 30-170
ELECTRICAL SYSTEM 30-171
SET AND ADJUST EACH EQUIPMENT 30-171
SET AND OPERATE MACHINE MONITOR 30-173
METHOD FOR STARTING UP KOMTRAX TERMINAL 30-267
ADJUST REARVIEW CAMERA ANGLE 30-272
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30-274
HANDLE BATTERY DISCONNECT SWITCH 30-275
TEST DIODES 30-276
Pm CLINIC 30-277
Pm CLINIC SERVICE 30-277
40 TROUBLESHOOTING 40-1
CONTENTS 40-2
ABBREVIATION LIST 40-12
RELATED INFORMATION ON TROUBLESHOOTING 40-18
GENERAL TROUBLESHOOTING POINTS 40-18
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40-19
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-31
CHECKS BEFORE TROUBLESHOOTING 40-33
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-35
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40-37
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 40-62
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40-70
SYMPTOM AND TROUBLESHOOTING NUMBERS 40-72
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-76
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR
SYSTEM 40-78
CONNECTORS LIST AND LAYOUT 40-81
CONNECTOR CONTACT IDENTIFICATION 40-98
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-137
FUSE LOCATION TABLE 40-143
PRECAUTIONS FOR REPLACING KDOC 40-147
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 40-148
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 40-150
FAILURE CODES TABLE 40-156
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-174
FAILURE CODE [2F00MA] 40-174
FAILURE CODE [2F00MB] 40-177
FAILURE CODE [2G42ZG] 40-179
FAILURE CODE [2G43ZG] 40-181
FAILURE CODE [6091NX] 40-183
FAILURE CODE [7RHYKA] 40-185
FAILURE CODE [7RHYKB] 40-187
FAILURE CODE [7RHYKY] 40-189
FAILURE CODE [879AKA] 40-191
FAILURE CODE [879AKB] 40-193
FAILURE CODE [879BKA] 40-195
FAILURE CODE [879BKB] 40-197
FAILURE CODE [879CKA] 40-199
FAILURE CODE [879CKB] 40-201
00 INDEX AND FOREWORD INDEX
WA200-8 00-5
FAILURE CODE [879DKZ] 40-203
FAILURE CODE [879EMC] 40-205
FAILURE CODE [879FMC] 40-206
FAILURE CODE [989FN1] 40-207
FAILURE CODE [989L00] 40-208
FAILURE CODE [989M00] 40-209
FAILURE CODE [989N00] 40-210
FAILURE CODE [A1U0N3] 40-211
FAILURE CODE [A1U0N4] 40-213
FAILURE CODE [AB00KE] 40-215
FAILURE CODE [AB00KY] 40-217
FAILURE CODE [AQ10MB] 40-219
FAILURE CODE [AQ10N3] 40-221
FAILURE CODE [AS00R2] 40-223
FAILURE CODE [AS00R3] 40-224
FAILURE CODE [AS00R4] 40-225
FAILURE CODE [AS00R5] 40-226
FAILURE CODE [AS00R6] 40-227
FAILURE CODE [AS00ZK] 40-228
FAILURE CODE [AS10KM] 40-229
FAILURE CODE [AS10NR] 40-230
FAILURE CODE [AS10NT] 40-231
FAILURE CODE [B@BAZG] 40-232
FAILURE CODE [B@BCNS] 40-233
FAILURE CODE [B@BCZK] 40-234
FAILURE CODE [B@C6NS] 40-236
FAILURE CODE [B@CRNS] 40-238
FAILURE CODE [CA115] 40-239
FAILURE CODE [CA122] 40-240
FAILURE CODE [CA123] 40-242
FAILURE CODE [CA131] 40-244
FAILURE CODE [CA132] 40-246
FAILURE CODE [CA144] 40-249
FAILURE CODE [CA145] 40-251
FAILURE CODE [CA153] 40-253
FAILURE CODE [CA154] 40-255
FAILURE CODE [CA187] 40-257
FAILURE CODE [CA221] 40-259
FAILURE CODE [CA222] 40-261
FAILURE CODE [CA227] 40-263
FAILURE CODE [CA234] 40-265
FAILURE CODE [CA238] 40-266
FAILURE CODE [CA239] 40-267
FAILURE CODE [CA249] 40-268
FAILURE CODE [CA256] 40-270
FAILURE CODE [CA271] 40-272
FAILURE CODE [CA272] 40-274
FAILURE CODE [CA295] 40-276
FAILURE CODE [CA322] 40-277
FAILURE CODE [CA324] 40-279
FAILURE CODE [CA331] 40-281
FAILURE CODE [CA332] 40-283
FAILURE CODE [CA343] 40-285
FAILURE CODE [CA351] 40-286
FAILURE CODE [CA352] 40-287
FAILURE CODE [CA356] 40-289
FAILURE CODE [CA357] 40-291
FAILURE CODE [CA386] 40-293
INDEX 00 INDEX AND FOREWORD
00-6 WA200-8
FAILURE CODE [CA428] 40-294
FAILURE CODE [CA429] 40-296
FAILURE CODE [CA431] 40-298
FAILURE CODE [CA432] 40-301
FAILURE CODE [CA435] 40-305
FAILURE CODE [CA441] 40-307
FAILURE CODE [CA442] 40-309
FAILURE CODE [CA451] 40-310
FAILURE CODE [CA452] 40-312
FAILURE CODE [CA488] 40-314
FAILURE CODE [CA515] 40-315
FAILURE CODE [CA516] 40-317
FAILURE CODE [CA553] 40-319
FAILURE CODE [CA555] 40-320
FAILURE CODE [CA556] 40-321
FAILURE CODE [CA559] 40-322
FAILURE CODE [CA595] 40-325
FAILURE CODE [CA687] 40-327
FAILURE CODE [CA689] 40-329
FAILURE CODE [CA691] 40-332
FAILURE CODE [CA692] 40-334
FAILURE CODE [CA697] 40-336
FAILURE CODE [CA698] 40-337
FAILURE CODE [CA731] 40-338
FAILURE CODE [CA778] 40-340
FAILURE CODE [CA1117] 40-344
FAILURE CODE [CA1664] 40-346
FAILURE CODE [CA1669] 40-348
FAILURE CODE [CA1673] 40-349
FAILURE CODE [CA1677] 40-350
FAILURE CODE [CA1678] 40-351
FAILURE CODE [CA1682] 40-352
FAILURE CODE [CA1683] 40-357
FAILURE CODE [CA1684] 40-359
FAILURE CODE [CA1686] 40-361
FAILURE CODE [CA1691] 40-362
FAILURE CODE [CA1694] 40-364
FAILURE CODE [CA1695] 40-366
FAILURE CODE [CA1696] 40-367
FAILURE CODE [CA1712] 40-370
FAILURE CODE [CA1713] 40-373
FAILURE CODE [CA1714] 40-376
FAILURE CODE [CA1715] 40-377
FAILURE CODE [CA1776] 40-378
FAILURE CODE [CA1777] 40-381
FAILURE CODE [CA1843] 40-384
FAILURE CODE [CA1844] 40-386
FAILURE CODE [CA1885] 40-389
FAILURE CODE [CA1887] 40-391
FAILURE CODE [CA1896] 40-393
FAILURE CODE [CA1898] 40-394
FAILURE CODE [CA1938] 40-396
FAILURE CODE [CA1942] 40-398
FAILURE CODE [CA1961] 40-399
FAILURE CODE [CA1962] 40-400
FAILURE CODE [CA2185] 40-401
FAILURE CODE [CA2186] 40-403
FAILURE CODE [CA2198] 40-405
00 INDEX AND FOREWORD INDEX
WA200-8 00-7
FAILURE CODE [CA2272] 40-406
FAILURE CODE [CA2288] 40-408
FAILURE CODE [CA2311] 40-409
FAILURE CODE [CA2349] 40-410
FAILURE CODE [CA2353] 40-412
FAILURE CODE [CA2357] 40-414
FAILURE CODE [CA2373] 40-415
FAILURE CODE [CA2374] 40-417
FAILURE CODE [CA2375] 40-419
FAILURE CODE [CA2376] 40-421
FAILURE CODE [CA2387] 40-424
FAILURE CODE [CA2554] 40-425
FAILURE CODE [CA2555] 40-427
FAILURE CODE [CA2556] 40-429
FAILURE CODE [CA2634] 40-431
FAILURE CODE [CA2635] 40-433
FAILURE CODE [CA2636] 40-434
FAILURE CODE [CA2637] 40-436
FAILURE CODE [CA2771] 40-438
FAILURE CODE [CA2961] 40-442
FAILURE CODE [CA2973] 40-443
FAILURE CODE [CA2976] 40-444
FAILURE CODE [CA3142] 40-446
FAILURE CODE [CA3143] 40-447
FAILURE CODE [CA3144] 40-448
FAILURE CODE [CA3146] 40-451
FAILURE CODE [CA3147] 40-452
FAILURE CODE [CA3148] 40-453
FAILURE CODE [CA3151] 40-456
FAILURE CODE [CA3165] 40-464
FAILURE CODE [CA3228] 40-466
FAILURE CODE [CA3229] 40-468
FAILURE CODE [CA3231] 40-470
FAILURE CODE [CA3232] 40-472
FAILURE CODE [CA3235] 40-476
FAILURE CODE [CA3239] 40-478
FAILURE CODE [CA3241] 40-481
FAILURE CODE [CA3242] 40-484
FAILURE CODE [CA3251] 40-487
FAILURE CODE [CA3313] 40-489
FAILURE CODE [CA3314] 40-490
FAILURE CODE [CA3315] 40-491
FAILURE CODE [CA3419] 40-493
FAILURE CODE [CA3421] 40-495
FAILURE CODE [CA3497] 40-497
FAILURE CODE [CA3498] 40-498
FAILURE CODE [CA3545] 40-499
FAILURE CODE [CA3547] 40-501
FAILURE CODE [CA3558] 40-502
FAILURE CODE [CA3559] 40-504
FAILURE CODE [CA3562] 40-506
FAILURE CODE [CA3563] 40-508
FAILURE CODE [CA3567] 40-511
FAILURE CODE [CA3568] 40-515
FAILURE CODE [CA3571] 40-521
FAILURE CODE [CA3572] 40-523
FAILURE CODE [CA3574] 40-525
FAILURE CODE [CA3575] 40-528
INDEX 00 INDEX AND FOREWORD
00-8 WA200-8
FAILURE CODE [CA3577] 40-530
FAILURE CODE [CA3578] 40-532
FAILURE CODE [CA3582] 40-534
FAILURE CODE [CA3583] 40-541
FAILURE CODE [CA3596] 40-543
FAILURE CODE [CA3649] 40-546
FAILURE CODE [CA3681] 40-548
FAILURE CODE [CA3682] 40-553
FAILURE CODE [CA3713] 40-558
FAILURE CODE [CA3717] 40-561
FAILURE CODE [CA3718] 40-562
FAILURE CODE [CA3724] 40-563
FAILURE CODE [CA3725] 40-564
FAILURE CODE [CA3741] 40-567
FAILURE CODE [CA3748] 40-568
FAILURE CODE [CA3755] 40-570
FAILURE CODE [CA3866] 40-572
FAILURE CODE [CA3868] 40-575
FAILURE CODE [CA4152] 40-579
FAILURE CODE [CA4155] 40-583
FAILURE CODE [CA4156] 40-586
FAILURE CODE [CA4157] 40-589
FAILURE CODE [CA4159] 40-591
FAILURE CODE [CA4164] 40-592
FAILURE CODE [CA4165] 40-594
FAILURE CODE [CA4166] 40-596
FAILURE CODE [CA4168] 40-597
FAILURE CODE [CA4169] 40-600
FAILURE CODE [CA4171] 40-602
FAILURE CODE [CA4249] 40-604
FAILURE CODE [CA4251] 40-606
FAILURE CODE [CA4261] 40-608
FAILURE CODE [CA4277] 40-611
FAILURE CODE [CA4459] 40-615
FAILURE CODE [CA4461] 40-617
FAILURE CODE [CA4533] 40-620
FAILURE CODE [CA4534] 40-621
FAILURE CODE [CA4731] 40-622
FAILURE CODE [CA4732] 40-623
FAILURE CODE [CA4739] 40-624
FAILURE CODE [CA4768] 40-625
FAILURE CODE [CA4769] 40-627
FAILURE CODE [CA4842] 40-630
FAILURE CODE [CA4952] 40-633
FAILURE CODE [CA5115] 40-635
FAILURE CODE [CA5179] 40-638
FAILURE CODE [CA5181] 40-640
FAILURE CODE [CA5387] 40-642
FAILURE CODE [CA5388] 40-644
FAILURE CODE [CA5389] 40-647
FAILURE CODE [CA5391] 40-649
FAILURE CODE [CA5392] 40-653
FAILURE CODE [CA5393] 40-655
FAILURE CODE [CA5394] 40-658
FAILURE CODE [CA5395] 40-661
FAILURE CODE [CA5396] 40-664
FAILURE CODE [CA5631] 40-665
FAILURE CODE [CA5632] 40-667
00 INDEX AND FOREWORD INDEX
WA200-8 00-9
FAILURE CODE [CA5938] 40-668
FAILURE CODE [D110L4] 40-670
FAILURE CODE [D160KA] 40-672
FAILURE CODE [D160KY] 40-674
FAILURE CODE [D191KA] 40-675
FAILURE CODE [D191KB] 40-677
FAILURE CODE [D191KY] 40-679
FAILURE CODE [D192KA] 40-680
FAILURE CODE [D192KB] 40-681
FAILURE CODE [D192KY] 40-682
FAILURE CODE [D19JKZ] 40-683
FAILURE CODE [D1B0KA] 40-685
FAILURE CODE [D1B0KB] 40-687
FAILURE CODE [D1B0KY] 40-689
FAILURE CODE [D1B0MC] 40-691
FAILURE CODE [D1E6KA] 40-693
FAILURE CODE [D1E6KB] 40-695
FAILURE CODE [D1E6KY] 40-697
FAILURE CODE [D5ZHKA] 40-699
FAILURE CODE [D5ZHKB] 40-701
FAILURE CODE [D5ZHL6] 40-703
FAILURE CODE [D811MC] 40-705
FAILURE CODE [D862KA] 40-706
FAILURE CODE [D8ALKA] 40-707
FAILURE CODE [D8ALKB] 40-709
FAILURE CODE [D8AQK4] 40-711
FAILURE CODE [D8AQKR] 40-715
FAILURE CODE [DAF0KT] 40-719
FAILURE CODE [DAF0MB] 40-720
FAILURE CODE [DAF0MC] 40-721
FAILURE CODE [DAF3KK] 40-722
FAILURE CODE [DAF8KB] 40-724
FAILURE CODE [DAFDKB] 40-726
FAILURE CODE [DAFGMC] 40-728
FAILURE CODE [DAFLKA] 40-729
FAILURE CODE [DAFLKB] 40-731
FAILURE CODE [DAFQKR] 40-733
FAILURE CODE [DAJ0KK] 40-738
FAILURE CODE [DAJ0KT] 40-741
FAILURE CODE [DAJ0MC] 40-742
FAILURE CODE [DAJ1KA] 40-743
FAILURE CODE [DAJ2KK] 40-745
FAILURE CODE [DAJ4KB] 40-748
FAILURE CODE [DAJ4KZ] 40-750
FAILURE CODE [DAJ5KX] 40-752
FAILURE CODE [DAJ6KX] 40-754
FAILURE CODE [DAJ9KQ] 40-756
FAILURE CODE [DAJLKA] 40-757
FAILURE CODE [DAJLKB] 40-759
FAILURE CODE [DAJQKR] 40-761
FAILURE CODE [DAJRKR] 40-766
FAILURE CODE [DAJRMA] 40-771
FAILURE CODE [DAZ9KQ] 40-772
FAILURE CODE [DAZQKR] 40-773
FAILURE CODE [DB2QKR] 40-777
FAILURE CODE [DB2RKR] 40-783
FAILURE CODE [DDAAL6] 40-788
FAILURE CODE [DDB6L4] 40-790
INDEX 00 INDEX AND FOREWORD
00-10 WA200-8
FAILURE CODE [DDD7KA] 40-792
FAILURE CODE [DDD7KY] 40-794
FAILURE CODE [DDE5MA] 40-796
FAILURE CODE [DDE7KA] 40-798
FAILURE CODE [DDE7KB] 40-800
FAILURE CODE [DDK3KA] 40-802
FAILURE CODE [DDK3KB] 40-805
FAILURE CODE [DDK6KA] 40-808
FAILURE CODE [DDK6KB] 40-811
FAILURE CODE [DDNRLD] 40-814
FAILURE CODE [DDS5L6] 40-816
FAILURE CODE [DF10KA] 40-818
FAILURE CODE [DF10KB] 40-821
FAILURE CODE [DGH1KX] 40-824
FAILURE CODE [DGR2KB] 40-826
FAILURE CODE [DGR2KZ] 40-828
FAILURE CODE [DHH1KX] 40-830
FAILURE CODE [DHH1KY] 40-832
FAILURE CODE [DHTCL6] 40-834
FAILURE CODE [DJF1KA] 40-836
FAILURE CODE [DK55KA] 40-837
FAILURE CODE [DK55KY] 40-840
FAILURE CODE [DK55L5] 40-843
FAILURE CODE [DK5DKA] 40-844
FAILURE CODE [DK5DKY] 40-847
FAILURE CODE [DK5DL8] 40-850
FAILURE CODE [DK5EKA] 40-854
FAILURE CODE [DK5EKY] 40-857
FAILURE CODE [DLM3KA] 40-860
FAILURE CODE [DLM3LC] 40-861
FAILURE CODE [DLT3KX] 40-863
FAILURE CODE [DLT4KX] 40-865
FAILURE CODE [DLT4L0] 40-867
FAILURE CODE [DLT4LC] 40-868
FAILURE CODE [DPQ1KR] 40-870
FAILURE CODE [DPQ2KR] 40-873
FAILURE CODE [DPQ3KR] 40-876
FAILURE CODE [DSJ0KR] 40-880
FAILURE CODE [DT22KB] 40-885
FAILURE CODE [DV00KB] 40-887
FAILURE CODE [DW26KA] 40-888
FAILURE CODE [DW26KB] 40-890
FAILURE CODE [DW26KY] 40-892
FAILURE CODE [DW44KA] 40-894
FAILURE CODE [DW44KB] 40-896
FAILURE CODE [DW44KY] 40-898
FAILURE CODE [DWM1KA] 40-899
FAILURE CODE [DWM1KB] 40-900
FAILURE CODE [DWM1KY] 40-902
FAILURE CODE [DWN6KA] 40-903
FAILURE CODE [DWN6KB] 40-905
FAILURE CODE [DWN6KY] 40-906
FAILURE CODE [DWN7KA] 40-907
FAILURE CODE [DWN7KB] 40-909
FAILURE CODE [DWN7KY] 40-910
FAILURE CODE [DWN8KA] 40-911
FAILURE CODE [DWN8KB] 40-913
FAILURE CODE [DWN8KY] 40-914
00 INDEX AND FOREWORD INDEX
WA200-8 00-11
FAILURE CODE [DWPBKA] 40-915
FAILURE CODE [DWPBKB] 40-917
FAILURE CODE [DWPBKY] 40-919
FAILURE CODE [DX19KA] 40-921
FAILURE CODE [DX19KB] 40-924
FAILURE CODE [DX19KY] 40-926
FAILURE CODE [DX20KA] 40-928
FAILURE CODE [DX20KB] 40-930
FAILURE CODE [DX20KY] 40-932
FAILURE CODE [DXH7KA] 40-934
FAILURE CODE [DXH7KB] 40-936
FAILURE CODE [DXH7KY] 40-938
FAILURE CODE [DXH8KA] 40-940
FAILURE CODE [DXH8KB] 40-942
FAILURE CODE [DXH8KY] 40-944
FAILURE CODE [DXHJKA] 40-946
FAILURE CODE [DXHJKB] 40-948
FAILURE CODE [DXHJKY] 40-950
FAILURE CODE [DXHKKA] 40-952
FAILURE CODE [DXHKKB] 40-954
FAILURE CODE [DXHKKY] 40-956
FAILURE CODE [H2K0KA] 40-958
FAILURE CODE [H2K0KY] 40-960
FAILURE CODE [J141N1] 40-962
FAILURE CODE [LA00L3] 40-963
FAILURE CODE [M100N1] 40-964
FAILURE CODE [M400N1] 40-965
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-966
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-966
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40-972
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40-975
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 40-978
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING
40-980
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 40-983
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT
OR FLICKERS) 40-985
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 40-987
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 40-989
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 40-992
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 40-996
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR
SWITCH DOES NOT OPERATE PROPERLY 40-998
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION
40-1001
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 40-1004
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED
PROPERLY 40-1007
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 40-1008
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 40-1011
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 40-1014
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 40-1019
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 40-1023
E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP 40-1025
E-22 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET
TO ON (PARKING) POSITION 40-1026
E-23 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE
CAUTION LAMP DOES NOT LIGHT UP 40-1030
INDEX 00 INDEX AND FOREWORD
00-12 WA200-8
E-24 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE
CAUTION LAMP DOES NOT LIGHT UP 40-1031
E-25 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE
CAUTION LAMP DOES NOT LIGHT UP 40-1032
E-26 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 40-1033
E-27 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 40-1035
E-28 ALARM BUZZER DOES NOT SOUND 40-1036
E-29 ALARM BUZZER DOES NOT STOP SOUNDING 40-1037
E-30 WHEN THE SECONDARY HST TRAVEL SWITCH IS OPERATED, IT DOES NOT WORK OR
WHEN THE SECONDARY HST TRAVEL SWITCH IS NOT OPERATED, IT WORKS 40-1038
E-31 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH
40-1041
E-32 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED 40-1043
E-33 THE BOOM KICK-OUT DOES NOT WORK OR CANNOT BE RELEASED 40-1046
E-34 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE
TRAVELING WHEN PARKING BRAKE IS RELEASED 40-1048
E-35 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED
40-1051
E-36 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX TRACTION SWITCH IS TURNED
ON 40-1053
E-37 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 40-1055
E-38 HORN DOES NOT SOUND 40-1057
E-39 HORN DOES NOT STOP SOUNDING 40-1060
E-40 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 40-1062
E-41 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 40-1064
E-42 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT 40-1068
E-43 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 40-1072
E-44 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 40-1074
E-45 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 40-1076
E-46 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT 40-1081
E-47 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT40-1085
E-48 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT 40-1088
E-49 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT 40-1091
E-50 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 40-1095
E-51 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 40-1099
E-52 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 40-1103
E-53 FRONT WIPER DOES NOT OPERATE 40-1105
E-54 REAR WIPER DOES NOT OPERATE 40-1109
E-55 WINDOW WASHER DOES NOT OPERATE 40-1112
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-1115
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-1116
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-1116
FAILURE MODE AND CAUSE TABLE 40-1117
H-1 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE 40-1130
H-2 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY) 40-1132
H-3 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY) 40-1133
H-4 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS
LOW 40-1134
H-5 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE
NORMALLY) 40-1137
H-6 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD
NORMALLY) 40-1139
H-7 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 40-1140
H-8 MACHINE DOES NOT TURN 40-1142
H-9 STEERING WHEEL IS HEAVY TO OPERATE 40-1143
H-10 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS 40-1144
H-11 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS 40-1145
H-12 WHEEL BRAKES DO NOT WORK OR ARE WEAK 40-1146
00 INDEX AND FOREWORD INDEX
WA200-8 00-13
H-13 WHEEL BRAKES ARE NOT RELEASED OR DRAG 40-1148
H-14 PARKING BRAKE DOES NOT WORK OR IT IS WEAK 40-1149
H-15 PARKING BRAKE IS NOT RELEASED OR DRAGS 40-1150
H-16 BOOM DOES NOT RISE 40-1152
H-17 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE 40-1154
H-18 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 40-1156
H-19 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 40-1157
H-20 HYDRAULIC DRIFT OF BOOM IS LARGE 40-1159
H-21 BOOM MOVES UP AND DOWN DURING OPERATION 40-1160
H-22 BUCKET DOES NOT TILT BACK 40-1161
H-23 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 40-1163
H-24 BUCKET DECELERATES DURING TILT-BACK OPERATION 40-1165
H-25 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 40-1166
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE 40-1168
H-27 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE
IN HOLD) 40-1169
H-28 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO
MOVE 40-1170
H-29 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE
STOPS 40-1171
H-30 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS
40-1172
H-31 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT
MOVES 40-1174
H-32 E C S S (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES
40-1175
H-33 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 40-1176
H-34 UNUSUAL NOISE IS HEARD FROM AROUND FAN 40-1178
TROUBLESHOOTING OF ENGINE (S-MODE) 40-1179
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-1179
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-1180
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40-1181
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) 40-1182
S-4 ENGINE STARTABILITY IS POOR 40-1184
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-1186
S-6 ENGINE STOPS DURING OPERATION 40-1188
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 40-1190
S-8 ENGINE LACKS POWER 40-1191
S-9 EXHAUST SMOKE IS BLACK 40-1193
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-1195
S-11 OIL BECOMES CONTAMINATED QUICKLY 40-1196
S-12 FUEL CONSUMPTION IS EXCESSIVE 40-1197
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-1198
S-14 OIL PRESSURE DROPS 40-1199
S-15 FUEL MIXES INTO ENGINE OIL 40-1201
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40-1202
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40-1203
S-18 UNUSUAL NOISE IS HEARD 40-1204
S-19 VIBRATION IS EXCESSIVE 40-1205
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-1206
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 40-1207
S-22 ACTIVE REGENERATION TAKES TIME 40-1208
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 40-1209
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 40-1210
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 40-1212
INDEX 00 INDEX AND FOREWORD
00-14 WA200-8
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 40-1213
50 DISASSEMBLY AND ASSEMBLY 50-1
CONTENTS 50-2
ABBREVIATION LIST 50-6
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-12
HOW TO READ THIS MANUAL 50-12
COATING MATERIALS LIST 50-14
SPECIAL TOOLS LIST 50-18
SKETCHES OF SPECIAL TOOLS 50-39
ENGINE AND COOLING SYSTEM 50-49
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50-49
REMOVE AND INSTALL INJECTOR ASSEMBLY 50-62
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 50-85
REMOVE AND INSTALL EGR VALVE ASSEMBLY 50-132
REMOVE AND INSTALL EGR COOLER ASSEMBLY 50-139
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 50-154
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 50-158
REMOVE AND INSTALL ALTERNATOR BELT 50-162
REMOVE AND INSTALL ALTERNATOR ASSEMBLY 50-171
REMOVE AND INSTALL AUTOMATIC TENSIONER 50-175
REMOVE AND INSTALL RADIATOR ASSEMBLY 50-185
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 50-199
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 50-208
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 50-213
REMOVE AND INSTALL ENGINE ASSEMBLY 50-218
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 50-257
REMOVE AND INSTALL ENGINE REAR OIL SEAL 50-269
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 50-276
REMOVE AND INSTALL KDOC ASSEMBLY 50-300
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY 50-317
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 50-342
REMOVE AND INSTALL FUEL TANK ASSEMBLY 50-352
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 50-361
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 50-377
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 50-382
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 50-390
REMOVE AND INSTALL SCR ASSEMBLY 50-392
REMOVE AND INSTALL KCCV ASSEMBLY 50-413
REMOVE AND INSTALL VGT ASSEMBLY 50-417
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 50-448
REMOVE AND INSTALL AdBlue/DEF INJECTOR 50-461
REMOVE AND INSTALL AdBlue/DEF PUMP 50-467
REMOVE AND INSTALL AdBlue/DEF HOSE 50-476
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 50-497
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 50-505
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 50-512
POWER TRAIN 50-516
REMOVE AND INSTALL HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND
COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY 50-516
REMOVE AND INSTALL HST MOTOR1 ASSEMBLY 50-525
REMOVE AND INSTALL HST MOTOR2 ASSEMBLY 50-530
REMOVE AND INSTALL TRANSFER ASSEMBLY 50-534
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY 50-550
REMOVE AND INSTALL PARKING BRAKE ASSEMBLY 50-584
REMOVE AND INSTALL PARKING BRAKE CYLINDER ASSEMBLY 50-588
DISSEMBLE AND ASSEMBLE PARKING BRAKE ASSEMBLY 50-590
REMOVE AND INSTALL FRONT AXLE ASSEMBLY 50-598
REMOVE AND INSTALL REAR AXLE ASSEMBLY 50-602
00 INDEX AND FOREWORD INDEX
WA200-8 00-15
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY 50-607
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY 50-620
UNDERCARRIAGE AND FRAME 50-657
REMOVE AND INSTALL CENTER HINGE PIN 50-657
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 50-678
HYDRAULIC SYSTEM 50-703
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 50-703
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 50-716
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY 50-726
WORK EQUIPMENT 50-737
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 50-737
CAB AND ITS ATTACHMENTS 50-753
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 50-753
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 50-779
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50-789
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 50-802
REMOVE AND INSTALL SEAT BELT 50-804
ELECTRICAL SYSTEM 50-806
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 50-806
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 50-815
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY 50-819
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 50-822
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-827
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 50-833
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 50-836
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 50-839
REMOVE AND INSTALL SCR OUTLET NOx SENSOR 50-846
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 50-853
60 MAINTENANCE STANDARD 60-1
CONTENTS 60-2
ABBREVIATION LIST 60-3
ENGINE AND COOLING SYSTEM 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT 60-9
MAINTENANCE STANDARD OF DAMPER 60-10
MAINTENANCE STANDARD OF COOLING FAN MOTOR 60-11
POWER TRAIN 60-15
MAINTENANCE STANDARD OF DRIVE SHAFT 60-15
MAINTENANCE STANDARD OF TRANSFER 60-16
MAINTENANCE STANDARD OF TRANSFER MOUNT 60-25
MAINTENANCE STANDARD OF FRONT AXLE 60-26
MAINTENANCE STANDARD OF REAR AXLE 60-27
MAINTENANCE STANDARD OF FRONT TORQUE PROPORTIONING DIFFERENTIAL 60-28
MAINTENANCE STANDARD OF REAR TORQUE PROPORTIONING DIFFERENTIAL 60-30
MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL 60-32
MAINTENANCE STANDARD OF FRONT FINAL DRIVE 60-34
MAINTENANCE STANDARD OF REAR FINAL DRIVE 60-36
STEERING SYSTEM 60-38
MAINTENANCE STANDARD OF STEERING COLUMN 60-38
MAINTENANCE STANDARD OF PRIORITY VALVE 60-39
MAINTENANCE STANDARD OF STEERING CYLINDER 60-40
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE 60-42
BRAKE SYSTEM 60-43
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE 60-43
MAINTENANCE STANDARD OF SLACK ADJUSTER 60-44
MAINTENANCE STANDARD OF FRONT BRAKE 60-45
MAINTENANCE STANDARD OF REAR BRAKE 60-46
MAINTENANCE STANDARD OF PARKING BRAKE 60-47
UNDERCARRIAGE AND FRAME 60-48
INDEX 00 INDEX AND FOREWORD
00-16 WA200-8
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 60-48
HYDRAULIC SYSTEM 60-53
MAINTENANCE STANDARD OF HYDRAULIC TANK 60-53
MAINTENANCE STANDARD OF STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN,
AND TRANSFER LUBRICATION PUMP 60-54
MAINTENANCE STANDARD OF CONTROL VALVE 60-56
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE 60-59
MAINTENANCE STANDARD OF ATTACHMENT EPC SOLENOID VALVE 60-61
WORK EQUIPMENT 60-62
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60-62
MAINTENANCE STANDARD OF BUCKET 60-65
MAINTENANCE STANDARD OF LIFT CYLINDER 60-66
MAINTENANCE STANDARD OF BUCKET CYLINDER 60-67
MAINTENANCE STANDARD OF COUPLER PLUNGER 60-68
CAB AND ITS ATTACHMENTS 60-69
MAINTENANCE STANDARD OF CAB MOUNT 60-69
80 APPENDIX 80-1
CONTENTS 80-2
ABBREVIATION LIST 80-4
AIR CONDITIONER SYSTEM 80-10
PRECAUTIONS FOR REFRIGERANT 80-10
AIR CONDITIONER COMPONENT 80-11
SPECIFICATIONS OF AIR CONDITIONER 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80-14
OUTLINE OF REFRIGERATION CYCLE 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80-17
AIR CONDITIONER UNIT 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT 80-19
AIR CONDITIONER CONTROLLER 80-23
COMPRESSOR 80-24
CONDENSER 80-25
RECEIVER DRIER 80-26
SENSORS FOR AIR CONDITIONER SYSTEM 80-27
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
80-28
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 80-30
AIR CONDITIONER SYSTEM DIAGRAM 80-33
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 80-34
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
80-36
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 80-42
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR 80-43
CHECK TEMPERATURE CONTROL FUNCTION 80-44
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION 80-44
TEST VENT (MODE) CHANGEOVER 80-46
METHOD FOR TESTING VENT (MODE) CHANGEOVER 80-46
TESTING FRESH/RECIRC AIR CHANGEOVER 80-48
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 80-48
TEST EVAPORATOR TEMPERATURE SENSOR 80-50
TEST RELAYS 80-52
METHOD FOR TESTING RELAYS 80-52
AIR CONDITIONER TROUBLESHOOTING CHART 1 80-54
AIR CONDITIONER TROUBLESHOOTING CHART 2 80-55
FAILURE CODE [879AKA] 80-58
FAILURE CODE [879AKB] 80-60
FAILURE CODE [879BKA] 80-62
FAILURE CODE [879BKB] 80-64
00 INDEX AND FOREWORD INDEX
WA200-8 00-17
FAILURE CODE [879CKA] 80-66
FAILURE CODE [879CKB] 80-68
FAILURE CODE [879DKZ] 80-70
FAILURE CODE [879EMC] 80-72
FAILURE CODE [879FMC] 80-73
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
80-74
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
80-77
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) 80-80
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 80-84
TROUBLESHOOTING USING GAUGE PRESSURE 80-86
CONNECTION OF SERVICE TOOL 80-89
METHOD FOR CONNECTING SERVICE TOOL 80-90
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER
PIPINGS 80-91
HANDLE COMPRESSOR OIL 80-93
90 CIRCUIT DIAGRAMS 90-1
CONTENTS 90-2
ABBREVIATION LIST 90-3
HYDRAULIC CIRCUIT DIAGRAM 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90-9
HYDRAULIC CIRCUIT DIAGRAM 90-13
ELECTRICAL CIRCUIT DIAGRAM 90-15
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90-15
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/10) 90-19
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/10) 90-21
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/10) 90-23
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/10) 90-25
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/10) 90-27
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/10) 90-29
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/10) 90-31
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/10) 90-33
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/10) 90-35
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/10) 90-37
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/9) 90-39
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/9) 90-41
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/9) 90-43
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/9) 90-45
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/9) 90-47
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/9) 90-49
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/9) 90-51
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/9) 90-53
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/9) 90-55
INDEX 1

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