Komatsu WA200-6, WA200PZ-6 70001 & Up SEN03862-02 (Preview)
COVER
00 INDEX AND FOREWORD
– 100 Index
— Composition of shop manual
— Table of contents
– 200 FOREWORD AND GENERAL INFORMATION
— SAFETY NOTICE
— HOW TO READ THE SHOP MANUAL
— EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
— HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
— HANDLING OF CONNECTORS NEWLY USED FOR ENGINES
— HOW TO READ ELECTRIC WIRE CODE
— PRECAUTIONS WHEN CARRYING OUT OPERATION
— METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
— STANDARD TIGHTENING TORQUE TABLE
— CONVERSION TABLE
01 SPECIFICATION
– 100 SPECIFICATION AND TECHNICAL DATA
— SPECIFICATION DIMENSION DRAWING
— SPECIFICATIONS
— WEIGHT TABLE
— TABLE OF FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
– 100 ENGINE AND COOLING SYSTEM
— ENGINE MOUNT AND TRANSFER MOUNT
— DAMPER
— COOLING SYSTEM
— COOLING SYSTEM HYDRAULIC PIPING DIAGRAM
— COOLING FAN MOTOR
– 200 POWER TRAIN
— POWER TRAIN
— POWER TRAIN SYSTEM DIAGRAM
— DRIVE SHAFT
— HST HYDRAULIC PIPING DIAGRAM
— HST PUMP
— HST MOTOR
— TRANSFER
— CLUTCH SOLENOID VALVE
— AXLE
— DIFFERENTIAL
— TORQUE PROPORTIONING
— LIMITED SLIP DIFFERENTIAL
— FINAL DRIVE
– 300 STEERING SYSTEM
— STEERING PIPING DIAGRAM
— STEERING COLUMN
— PRIORITY VALVE
— ORBIT-ROLL VALVE
— 2-WAY RESTRICTOR VALVE
— CUSHION VALVE
— STEERING CYLINDER
— EMERGENCY STEERING PIPING DIAGRAM
— EMERGENCY STEERING VALVE
— STEERING RELIEF VALVE
– 400 BRAKE SYSTEM
— BRAKE PIPING DIAGRA
— CHARGE VALVE
— BRAKE VALVE
— INCHING VALVE
— ACCUMULATOR (FOR BRAKE)
— SLACK ADJUSTER
— BRAKE
— PARKING BRAKE CONTROL
— PARKING BRAKE
– 500 UNDERCARRIAGE AND FRAME
— AXLE MOUNT AND CENTER HINGE PIN
— TIRES
– 600 HYDRAULIC SYSTEM
— WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
— WORK EQUIPMENT CONTROL LEVER LINKAGE
— HYDRAULIC TANK
— 4-GEAR PUMP
— WORK EQUIPMENT CONTROL VALVE
— PPC VALVE
— LOCK VALVE
— ACCUMULATOR (FOR PPC CIRCUIT)
— BYPASS VALVE
— QUICK COUPLER SOLENOID VALVE
— ECSS VALVE
— ACCUMULATOR (FOR ECSS)
– 700 WORK EQUIPMENT
— WORK EQUIPMENT LINKAGE
— BUCKET
— BUCKET POSITIONER AND BOOM KICK-OUT
— WORK EQUIPMENT CYLINDER
– 800 CAB AND ITS ATTACHMENTS
— CAB
— AIR CONDITIONER
– 910 ELECTRICAL SYSTEM, PART 1
— MACHINE MONITOR SYSTEM
— MACHINE MONITOR
– 920 ELECTRICAL SYSTEM, PART 2
— ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)
— HST CONTROLLER
— ECSS SYSTEM
— KOMTRAX SYSTEM
— ENGINE STARTING CIRCUIT
— ENGINE STOPPING CIRCUIT
— PREHEATING CIRCUIT
— ENGINE OUTPUT DERATING FUNCTION
— AUTOMATIC WARM-UP FUNCTION
— PARKING BRAKE CIRCUIT
— COUPLER PLUNGER CONTROL SYSTEM
— MULTI-FUNCTION KNOB
— MAX. TRACTION SWITCH
— SENSOR
20 STANDARD VALUE TABLE
– 100 STANDARD SERVICE VALUE TABLE
— STANDARD SERVICE VALUE TABLE FOR ENGINE
— STANDARD SERVICE VALUE TABLE FOR CHASSIS
30 TESTING AND ADJUSTING
– 110 TESTING AND ADJUSTING, PART 1
— TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
— Sketches of special tools
— Measuring engine speed
— Measuring exhaust gas color
— ADJUSTING VALVE CLEARANCE
— MEASURING COMPRESSION PRESSURE
— MEASURING BLOW-BY PRESSURE
— TESTING ENGINE OIL PRESSURE
— MEASURING INTAKE AIR (BOOST) PRESSURE
— HANDLING FUEL SYSTEM EQUIPMENT
— RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM
— MEASURING FUEL PRESSURE
— MEASURING FUEL RETURN RATE AND LEAKAGE
— BLEEDING AIR FROM FUEL CIRCUIT
— Checking leakage in fuel system
— Handling cylinder cut-out mode operation
— Handling no-injection cranking operation
— HANDLING CONTROLLER VOLTAGE CIRCUIT
— CHECK OF MUFFLER AND MUFFLER STACK FOR LOOSENESS AND DAMAGE
— CHECK OF MUFFLER FUNCTION
— CHECK OF INSTALLED CONDITION OF CYLINDER HEAD AND MANIFOLDS
— CHECK OF ENGINE PIPING FOR DAMAGE AND LOOSENESS
— TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
— REPLACING ALTERNATOR BELT
– 120 TESTING AND ADJUSTING, PART 2
— CHECKING OPERATING FORCE OF ACCELERATOR PEDAL
— CHECKING DIRECTIONAL LEVER
— TESTING AND ADJUSTING HST OIL PRESSURE
— TESTING CLUTCH CONTROL PRESSURE
— TESTING AND ADJUSTING STEERING WHEEL
— TESTING AND ADJUSTING STEERING OIL PRESSURE
— BLEEDING AIR FROM STEERING CIRCUIT
— TESTING HYDRAULIC FAN
— MEASURING BRAKE PEDAL
— TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
— MEASURING BRAKE PERFORMANCE
— TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
— TESTING WHEEL BRAKE OIL PRESSURE
— TESTING WEAR OF BRAKE DISC
— BLEEDING AIR FROM WHEEL BRAKE CIRCUIT
— RELEASING RESIDUAL PRESSURE IN BRAKE ACCUMULATOR CIRCUIT
— TESTING PARKING BRAKE PERFORMANCE
— TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE
— MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER
— TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
— TESTING WORK EQUIPMENT PPC OIL PRESSURE
— BLEEDING AIR FROM HYDRAULIC CIRCUIT
— RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
— TESTING AND ADJUSTING BUCKET POSITIONER
— TESTING AND ADJUSTING OF BOOM KICK-OUT SWITCH
— CHECKING PROXIMITY SWITCH OPERATION PILOT LAMP
— PROCEDURE FOR TESTING DIODES
— PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM
— STARTING KOMTRAX TERMINAL OPERATIONS
— INDICATOR LAMPS OF KOMTRAX TERMINAL
– 130 TESTING AND ADJUSTING, PART 3
— ADJUSTING MACHINE MONITOR
— ADJUSTING REPLACED, REASSEMBLED OR ADDED SENSOR, CONTROLLER, ETC. WITH MACHINE MONITOR
— SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS)
— PM CLINIC INSPECTION CHART
40 TROUBLESHOOTING
– 100 FAILURE CODE TABLE AND FUSE LOCATIONS
— FAILURE CODES TABLE
— FUSE LOCATIONS
– 200 General information on troubleshooting
— Points to remember when troubleshooting
— Sequence of events in troubleshooting
— Testing before troubleshooting
— Classification and procedures of troubleshooting
— Information contained in troubleshooting table
— Connection table for connector pin numbers
— T- branch box and T- branch adapter table
– 310 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1
— FAILURE CODE [2G40GZ] BRAKE: OIL PRESSURE REDUCTION
— FAILURE CODE [6091NX] HST FILTER: CLOGGING
— FAILURE CODE [989FN1] TRAVEL SPEED: OVERRUN ALARM
— FAILURE CODE [AB00L6] ALTERNATOR R SYSTEM: HOT SHORT
— FAILURE CODE [AB00MA] ALTERNATOR R SYSTEM: GROUND FAULT/DISCONNECTION CHARGE/LOW CHARGE VOLTAGE
— FAILURE CODE [B@BAZG] ENGINE: OIL PRESSURE REDUCTION
— FAILURE CODE [B@BCNS] ENGINE: OVERHEAT
— FAILURE CODE [B@BCZK] ENGINE: LOW COOLANT LEVEL
— FAILURE CODE [B@C6NS] FRONT BRAKE: HIGH OIL TEMPERATURE
— FAILURE CODE [B@CRNS] HST: HIGH OIL TEMPERATURE
– 320 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2
— FAILURE CODE [CA111] ABNORMALITY IN ENGINE CONTROLLER
— FAILURE CODE [CA115] ENGINE NE OR BKUP SPEED SENSOR ERROR
— FAILURE CODE [CA122] CHARGE PRESSURE SENSOR HIGH ERROR
— FAILURE CODE [CA123] CHARGE PRESSURE SENSOR LOW ERROR
— FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR
— FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR
— FAILURE CODE [CA144] COOLANT SENSOR HIGH ERROR
— FAILURE CODE [CA145] COOLANT SENSOR LOW ERROR
— FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR HIGH ERROR
— FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR LOW ERROR
— FAILURE CODE [CA155] DERATING OF SPEED BY ABNORMALLY HIGH CHARGE TEMPERATURE
— FAILURE CODE [CA187] SENSOR POWER SUPPLY 2 LOW ERROR
— FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR HIGH ERROR
— FAILURE CODE [CA222] ATMOSPHERIC SENSOR LOW ERROR
— FAILURE CODE [CA227] SENSOR POWER SUPPLY 2 HIGH ERROR
— FAILURE CODE [CA234] ENGINE OVERSPEED
— FAILURE CODE [CA238] NE SPEED SENSOR POWER SUPPLY ERROR
— FAILURE CODE [CA271] IMV (IMA) SHORT CIRCUIT
— FAILURE CODE [CA272] IMV (IMA) DISCONNECTION
— FAILURE CODE [CA322] INJECTOR #1 OPEN/SHORT ERROR
— FAILURE CODE [CA324] INJECTOR #3 OPEN/SHORT ERROR
— FAILURE CODE [CA331] INJECTOR #2 OPEN/SHORT ERROR
— FAILURE CODE [CA332] INJECTOR #4 OPEN/SHORT ERROR
— FAILURE CODE [CA342] CALIBRATION CODE INCONSISTENCY
— FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR
— FAILURE CODE [CA352] SENSOR POWER SUPPLY 1 LOW ERROR
— FAILURE CODE [CA386] SENSOR POWER SUPPLY 1 HIGH ERROR
– 330 Troubleshooting by failure code (Display of code), Part 3
— Failure code [CA428] Abnormally high level in water sensor
— Failure code [CA429] Abnormally low level in water sensor
— Failure code [CA431] Idle validation switch error
— Failure code [CA432] Idle validation action error
— Failure code [CA435] Engine oil pressure switch error
— Failure code [CA441] Battery voltage low error
— Failure code [CA442] Battery voltage high error
— Failure code [CA449] Common rail pressure high error 2
— Failure code [CA451] Common rail pressure sensor high error
— Failure code [CA452] Common rail pressure sensor low error
— Failure code [CA488] Derating of torque by abnormally high charge temperature
— Failure code [CA553] Common rail pressure high error 1
— Failure code [CA559] Supply pump pressure very low error
— Failure code [CA689] Engine Ne speed sensor error
— Failure code [CA731] Engine Bkup speed sensor phase error
— Failure code [CA757] All continuous data lost error
— Failure code [CA778] Engine Bkup speed sensor error
— Failure code [CA1633] KOMNET datalink timeout error
— Failure code [CA2185] Throttle sensor supply voltage high error
— Failure code [CA2186] Throttle sensor power supply low error
— Failure code [CA2249] Supply pump pressure very low error 2
— Failure code [CA2311] Abnormality in IMV (IMA) solenoid
— Failure code [CA2555] Intake heater relay disconnection error
— Failure code [CA2556] Intake heater relay short circuit error
– 340 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4
— FAILURE CODE [D160KY] BACKUP ALARM/LAMP RELAY 1 CIRCUIT: HOT SHORT
— FAILURE CODE [D192KY] ECSS SOLENOID RELAY: HOT SHORT
— FAILURE CODE [D1B0KA] HST SAFETY RELAY: DISCONNECTION
— FAILURE CODE [D1B0KB] HST SAFETY RELAY: GROUND FAULT
— FAILURE CODE [D1B0KY] HST SAFETY RELAY: HOT SHORT
— FAILURE CODE [D5ZHL6] IGN C SYSTEM: GROUND FAULT/DISCONNECTION
— FAILURE CODE [DAF3KK] UNSW POWER SUPPLY: GROUND FAULT/DISCONNECTION
— FAILURE CODE [DAFRKR] MACHINE MONITOR CAN-NET SIGNAL: DISCONNECTION
— FAILURE CODE [DAJ0KK] HST CONTROLLER POWER SUPPLY: LOW VOLTAGE
— FAILURE CODE [DAJ0KT] HST CONTROLLER MEMORY (EEPROM): ABNORMALITY
— FAILURE CODE [DAJ1L4] HST CONTROLLER MAIN POWER LINE: DISCONNECTION/GROUND FAULT
— FAILURE CODE [DAJ1L6] HST CONTROLLER MAIN POWER LINE: HOT SHORT
— FAILURE CODE [DAJ2KK] CONTROLLER SOLENOID POWER SUPPLY: LOW VOLTAGE
— FAILURE CODE [DAJ2L3] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: HOT SHORT IN WIRING HARNESS
— FAILURE CODE [DAJ2L4] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: DISCONNECTION/GROUND FAULT
— FAILURE CODE [DAJ5KX] SENSOR 5V POWER SUPPLY: OUT OF OUTPUT RANGE
— FAILURE CODE [DAJ9KQ] HST CONTROLLER MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS
— FAILURE CODE [DAJRKR] HST CONTROLLER CAN-NET SIGNAL: DISCONNECTION
— FAILURE CODE [DAJRMA] HST CONTROLLER: DISAGREEMENT IN OPTION SELECTION
– 350 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 5
— FAILURE CODE [DB2RKR] ENGINE CONTROLLER CAN-NET: DISCONNECTION IN SIGNAL LINE
— FAILURE CODE [DD1NL4] FAN AUTOMATIC REVERSE SWITCH SIGNAL: ABNORMALITY
— FAILURE CODE [DD1NLD] FAN REVERSE SWITCH SIGNAL: ABNORMALITY
— FAILURE CODE [DDB6KA] PARKING BRAKE SWITCH A: DISCONNECTION/HOT SHORT
— FAILURE CODE [DDB6KB] PARKING BRAKE SWITCH B: GROUND FAULT
— FAILURE CODE [DDB6KZ] PARKING BRAKE SWITCH (BOTTOM SWITCH) OR PARKING BRAKE REMINDER SWITCH (INTERMEDIATE SWITCH): TROUBLE
— FAILURE CODE [DDB6L0] PARKING BRAKE SWITCH A: GROUND FAULT
— FAILURE CODE [DDB6L4] PARKING BRAKE SWITCH B: DISCONNECTION/HOT SHORT
— FAILURE CODE [DDD7KX] TRAVEL SPEED CONTROL DIAL SIGNAL: DISCONNECTION/GROUND FAULT
— FAILURE CODE [DDD7KY] TRAVEL SPEED CONTROL DIAL SIGNAL: HOT SHORT
— FAILURE CODE [DDE5MA] EMERGENCY STEERING OPERATION SWITCH: DISCONNECTION
— FAILURE CODE [DDK3KA] DIRECTIONAL SELECTOR SWITCH: DISCONNECTION/HOT SHORT
— FAILURE CODE [DDK3KB] DIRECTIONAL SELECTOR SWITCH: GROUND FAULT
— FAILURE CODE [DDK6KA] FNR LEVER: DISCONNECTION/GROUND FAULT
— FAILURE CODE [DDK6KY] FNR LEVER: HOT SHORT
— FAILURE CODE [DDS5L6] STEERING: LOW OIL PRESSURE (OPERATION OF EMERGENCY STEERING)
– 360 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 6
— FAILURE CODE [DF10KA] TRAVEL SPEED RANGE SELECTOR SWITCH: DISCONNECTION/GROUND FAULT
— FAILURE CODE [DF10KB] TRAVEL SPEED RANGE SELECTOR SWITCH: HOT SHORT
— FAILURE CODE [DGH1KX] HST OIL TEMPERATURE SENSOR: GROUND FAULT
— FAILURE CODE [DGR2KB] BRAKE OIL TEMPERATURE SENSOR: GROUND FAULT
— FAILURE CODE [DGR2KZ] BRAKE OIL TEMPERATURE SENSOR: DISCONNECTION/HOT SHORT
— FAILURE CODE [DHH1KX] HST OIL PRESSURE SENSOR: DISCONNECTION/GROUND FAULT
— FAILURE CODE [DHH1KY] HST OIL PRESSURE SENSOR: HOT SHORT
— FAILURE CODE [DHTCL6] HST FILTER CLOGGING SENSOR: FUNCTIONAL DEFECT
— FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION/HOT SHORT
— FAILURE CODE [DLT3KX] TRAVEL SPEED SENSOR B: ABNORMALITY
— FAILURE CODE [DLT4KX] TRAVEL SPEED SENSOR A: ABNORMALITY
— FAILURE CODE [DLT4LC] TRAVEL SPEED SENSOR A & B: ABNORMALITY
— FAILURE CODE [DV00KY] ALARM BUZZER: HOT SHORT
— FAILURE CODE [DW26KA] MOTOR 2 SOLENOID: DISCONNECTION/GROUND FAULT
— FAILURE CODE [DW26KY] MOTOR 2 SOLENOID: HOT SHORT
— FAILURE CODE [DW7BKY] FAN REVERSE SOLENOID CIRCUIT: HOT SHORT
— FAILURE CODE [DW7BKZ] FAN REVERSE SOLENOID CIRCUIT: DISCONNECTION/GROUND FAULT
– 370 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 7
— FAILURE CODE [DX16KA] FAN EPC SOLENOID: DISCONNECTION
— FAILURE CODE [DX16KB] FAN EPC SOLENOID: GROUND FAULT
— FAILURE CODE [DX16KY] FAN EPC SOLENOID: HOT SHORT
— FAILURE CODE [DX19KA] MOTOR 1 SOLENOID: DISCONNECTION
— FAILURE CODE [DX19KB] MOTOR 1 SOLENOID: GROUND FAULT
— FAILURE CODE [DX19KY] MOTOR 1 SOLENOID: HOT SHORT
— FAILURE CODE [DX20KA] CLUTCH EPC SOLENOID: DISCONNECTION
— FAILURE CODE [DX20KB] CLUTCH EPC SOLENOID: GROUND FAULT
— FAILURE CODE [DX20KY] CLUTCH EPC SOLENOID: HOT SHORT
— FAILURE CODE [DXH7KB] REVERSE SOLENOID: GROUND FAULT
— FAILURE CODE [DXH7KZ] REVERSE SOLENOID: DISCONNECTION/HOT SHORT
— FAILURE CODE [DXH8KB] FORWARD SOLENOID: GROUND FAULT
— FAILURE CODE [DXH8KZ] FORWARD SOLENOID: DISCONNECTION/HOT SHORT
— FAILURE CODE [J141N1] STEERING PUMP: OVERRUN ALARM
— FAILURE CODE [M100N1] HST PUMP: OVERRUN ALARM
— FAILURE CODE [M400N1] MOTOR 1: OVERRUN ALARM
– 400 Troubleshooting of electrical system(E-mode)
— E-1 Engine does not start
— E-2. Preheater does not operate normally
— E-3 Travel speed is low or high
— E-4 ECSS does not operate
— E-5 ECSS keeps operating
— E-6 Defective boom kick-out function and cancellation
— E-7 Defective bucket positioner function and cancellation
— E-8 Defective lift arm FLOATING holding function and cancellation
— E-9 Travel direction selection system does not function
— E-10 Fan does not reverse
— E-11 Fan keeps rotating in reverse
— E-12 Wiper does not operate
— E-13 Windshield washer does not operate
— E-14 Headlamp, clearance lamp and tail lamp do not light up or go off
— E-15 Working lamp does not light up or go off
— E-16 Turn signal lamp and hazard lamp do not light up or go off
— E-17 Brake lamp does not light or it keeps lighting up
— E-18 Backup lamp does not light or it keeps lighting up
— E-19 Backup alarm does not sound or it keeps sounding
— E-20 Horn does not sound or it keeps sounding
— E-21 Alarm buzzer does not sound or it keeps sounding
— E-22 Air conditioner does not operate or stop
— E-23 The KOMTRAX system does not work properly
– 500 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
— METHOD OF USING TROUBLESHOOTING CHART
— FAILURE CODE AND CAUSE TABLE
— H-1 THE MACHINE DOES NOT START
— H-2 THE TRAVEL SPEED IS SLOW
— H-3 THE TRACTION FORCE IS WEAK
— H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY
— H-5 THE GEAR IS NOT SHIFTED
— H-6 THE STEERING WHEEL DOES NOT TURN
— H-7 THE STEERING WHEEL IS HEAVY
— H-8 STEERING WHEEL SHAKES OR JERKS
— H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING
— H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL
— H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED
— H-12 THE LIFT ARM DOES NOT RISE OR LOWER
— H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT
— H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT
— H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)
— H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN
— H-17 THE LIFT ARM WOBBLES DURING OPERATION
— H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM “ HOLD ” TO “ RAISE, ” THE LIFT ARM FALLS TEMPORARILY
— H-19 THE BUCKET DOES NOT TILT BACK
— H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT
— H-21 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK
— H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET
— H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN
— H-24 THE BUCKET WOBBLES DURING TRAVEL WITH LOAD (THE WORK EQUIPMENT VALVE IS SET TO “ HOLD ” )
— H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM “ HOLD ” TO “ TILT, ” THE BUCKET FALLS TEMPORARILY
— H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY
— H-27 THE ECSS DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES
— H-28 FAN REVOLUTION IS ABNORMAL (FAN SOUND/VIBRATION IS ABNORMALLY LARGE OR ENGINE OVERHEATS)
– 600 TROUBLESHOOTING OF ENGINE (S-MODE)
— METHOD OF USING TROUBLESHOOTING CHARTS
— S-1 STARTING PERFORMANCE IS POOR
— S-2 ENGINE DOES NOT START
— S-3 ENGINE DOES NOT PICK UP SMOOTHLY
— S-4 ENGINE STOPS DURING OPERATIONS
— S-5 ENGINE DOES NOT ROTATE SMOOTHLY
— S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
— S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
— S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
— S-9 OIL BECOMES CONTAMINATED QUICKLY
— S-10 FUEL CONSUMPTION IS EXCESSIVE
— S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
— S-12 OIL PRESSURE DROPS
— S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)
— S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
— S-15 ABNORMAL NOISE IS MADE
— S-16 VIBRATION IS EXCESSIVE
50 DISASSEMBLY AND ASSEMBLY
– 100 GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
— HOW TO READ THIS MANUAL
— COATING MATERIALS LIST
— SPECIAL TOOL LIST
— SKETCHES OF SPECIAL TOOLS
– 200 ENGINE AND COOLING SYSTEM
— REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
— REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
— REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
— REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
— REMOVAL AND INSTALLATION OF RADIATOR
— REMOVAL AND INSTALLATION OF AIR AFTERCOOLER
— REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
— REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
— REMOVAL AND INSTALLATION OF ENGINE FRONT OIL SEAL ASSEMBLY
— REMOVAL AND INSTALLATION OF ENGINE REAR OIL SEAL ASSEMBLY
— REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY
— REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
– 310 POWER TRAIN, PART 1
— DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY
— REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY
– 320 POWER TRAIN, PART 2
— REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY
— REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
– 400 UNDERCARRIAGE AND FRAME
— REMOVAL AND INSTALLATION OF CENTER HINGE PIN
— REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY
– 500 HYDRAULIC SYSTEM
— REMOVAL AND INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
— REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY
— REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
— REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY
— REMOVAL AND INSTALLATION OF HYDRAULIC TANK
— DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
– 600 WORK EQUIPMENT
— REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY
– 700 CAB AND ITS ATTACHMENTS
— REMOVAL AND INSTALLATION OF OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY
— REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)
— REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT
– 800 ELECTRICAL SYSTEM
— REMOVAL AND INSTALLATION OF MONITOR PANEL
— REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
— REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY
— REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL ASSEMBLY
90 DIAGRAMS AND DRAWINGS
– 100 HYDRAULIC DIAGRAMS AND DRAWINGS
— HYDRAULIC CIRCUIT DIAGRAM
– 200 ELECTRICAL DIAGRAMS AND DRAWINGS
— ELECTRICAL CIRCUIT DIAGRAM
— CONNECTOR LIST AND STEREOGRAM
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