Komatsu WA200-7 Install guide
WHEEL LOADER
SEN06503-05
WA200-7
SERIAL NUMBERS
80001
and up
00 Index and foreword
Index
00-2 WA200-7
Index and foreword
Index
00 Index and foreword
Index and foreword .................................................................................................................................00-2
Foreword, safety and general information.............................................................................................00-14
Important safety notice......................................................................................................................00-14
How to read the shop manual............................................................................................................00-21
Explanation of terms for maintenance standard................................................................................00-23
Handling equipment of fuel system devices......................................................................................00-25
Handling of intake system parts ........................................................................................................00-26
Handling of hydraulic equipment.......................................................................................................00-27
Method of disconnecting and connecting of push-pull type coupler..................................................00-29
Handling of electrical equipment .......................................................................................................00-32
How to read electric wire code ..........................................................................................................00-40
Precautions when performing operation............................................................................................00-43
Practical use of KOMTRAX...............................................................................................................00-48
Standard tightening torque table .......................................................................................................00-49
List of Abbreviation............................................................................................................................00-55
Conversion table................................................................................................................................00-59
01 Specifications
Specifications..........................................................................................................................................01-4
Specification dimension drawing.........................................................................................................01-4
Specifications ......................................................................................................................................01-6
Weight table.......................................................................................................................................01-14
Table of fuel, coolant, and lubricants.................................................................................................01-18
10 Structure and function
Engine and cooling system.....................................................................................................................10-4
VFT......................................................................................................................................................10-4
EGR system piping drawing................................................................................................................10-8
EGR system circuit diagram..............................................................................................................10-10
EGR valve .........................................................................................................................................10-12
EGR cooler........................................................................................................................................10-14
KCCV layout drawing ........................................................................................................................10-16
KCCV ventilator.................................................................................................................................10-19
KDOC muffler....................................................................................................................................10-23
Damper..............................................................................................................................................10-25
Cooling system..................................................................................................................................10-26
Cooling system hydraulic piping diagram..........................................................................................10-27
Cooling fan motor..............................................................................................................................10-28
Power train............................................................................................................................................10-37
Power train ........................................................................................................................................10-37
Power train system diagram..............................................................................................................10-38
Drive shaft .........................................................................................................................................10-40
HST hydraulic piping diagram ...........................................................................................................10-41
HST pump .........................................................................................................................................10-42
HST motor.........................................................................................................................................10-50
Transfer.............................................................................................................................................10-56
Clutch solenoid valve.........................................................................................................................10-62
Axle....................................................................................................................................................10-63
Differential .........................................................................................................................................10-65
Torque proportioning differential........................................................................................................10-68
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00 Index and foreword
Index
WA200-7 00-3
Limited slip differential.......................................................................................................................10-69
Final drive..........................................................................................................................................10-72
Steering system....................................................................................................................................10-75
Steering piping diagram ....................................................................................................................10-75
Orbitrol valve.....................................................................................................................................10-76
Steering column ................................................................................................................................10-84
Priority valve......................................................................................................................................10-85
Emergency steering valve.................................................................................................................10-88
Brake system........................................................................................................................................10-91
Brake piping diagram ........................................................................................................................10-91
Brake valve........................................................................................................................................10-92
Charge valve.....................................................................................................................................10-96
Accumulator (for brake)................................................................................................................... 10-100
Slack adjuster..................................................................................................................................10-101
Brake...............................................................................................................................................10-103
Parking brake control ......................................................................................................................10-106
Parking brake..................................................................................................................................10-107
Parking brake cylinder.....................................................................................................................10-108
Parking brake solenoid valve ..........................................................................................................10-109
Inching valve ...................................................................................................................................10-111
Undercarriage and frame....................................................................................................................10-112
Axle mount and center hinge pin..................................................................................................... 10-112
Hydraulic system.................................................................................................................................10-114
Hydraulic component layout............................................................................................................10-114
Work equipment control lever linkage.............................................................................................10-116
Hydraulic tank..................................................................................................................................10-117
Accumulator (for PPC circuit)..........................................................................................................10-119
Work equipment control valve.........................................................................................................10-120
PPC valve........................................................................................................................................ 10-133
Attachment EPC valve ....................................................................................................................10-139
Work equipment lock solenoid valve...............................................................................................10-140
ECSS valve.....................................................................................................................................10-141
Accumulator (for ECSS)..................................................................................................................10-143
2-way restrictor valve ......................................................................................................................10-144
Cushion valve..................................................................................................................................10-145
Accumulator (for oil cooler circuit)...................................................................................................10-146
Quadruple gear pump .....................................................................................................................10-147
Quick coupler solenoid valve...........................................................................................................10-148
Work equipment..................................................................................................................................10-149
Work equipment linkage..................................................................................................................10-149
Bucket .............................................................................................................................................10-151
Bucket positioner and boom kick-out ..............................................................................................10-152
Cab and its attachments.....................................................................................................................10-158
Cab.................................................................................................................................................. 10-158
Electrical system.................................................................................................................................10-159
Machine monitor system .................................................................................................................10-159
Machine monitor.............................................................................................................................. 10-164
Electrical system (HST controller system).......................................................................................10-186
System component parts.................................................................................................................10-202
HST controller .................................................................................................................................10-208
ECSS...............................................................................................................................................10-212
KOMTRAX system.......................................................................................................................... 10-214
Engine starting circuit......................................................................................................................10-217
Engine stopping circuit....................................................................................................................10-219
Preheating system........................................................................................................................... 10-220
Automatic preheating system..........................................................................................................10-221
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00 Index and foreword
Index
00-4 WA200-7
Manual preheating system ..............................................................................................................10-221
Engine output limit function .............................................................................................................10-222
Automatic warm-up function............................................................................................................10-222
Parking brake control system..........................................................................................................10-223
Multi-function mono-lever................................................................................................................10-227
Sensor.............................................................................................................................................10-229
20 Standard value table
Standard value table...............................................................................................................................20-3
Standard value table for engine...........................................................................................................20-3
Standard value table for machine........................................................................................................20-5
30 Testing and adjusting
Related information on testing and adjusting..........................................................................................30-4
Tools for testing and adjusting.............................................................................................................30-4
Engine and cooling system.....................................................................................................................30-7
Testing and adjusting engine speed....................................................................................................30-7
Testing exhaust gas temperature........................................................................................................30-9
Testing exhaust gas color................................................................................................................ .30-10
Testing and adjusting valve clearance ............................................................................................ .30-12
Testing compression pressure ........................................................................................................ .30-14
Testing blowby pressure.................................................................................................................. .30-17
Testing engine oil pressure ............................................................................................................. .30-18
Testing boost pressure.................................................................................................................... .30-19
Handling equipment of fuel system devices.................................................................................... .30-21
Releasing remaining pressure from fuel system ............................................................................. .30-21
Testing fuel pressure....................................................................................................................... .30-22
Testing fuel discharge, return and leakage ..................................................................................... .30-27
Bleeding air from fuel system.......................................................................................................... .30-32
Testing fuel circuit for leakage......................................................................................................... .30-34
Handling cylinder cutout mode operation........................................................................................ .30-35
Handling no-injection cranking operation ........................................................................................ .30-35
Testing KDPF and muffler stack for looseness and damage .......................................................... .30-36
Testing KDOC function.................................................................................................................... .30-36
Testing installed condition of cylinder heads and manifolds............................................................ .30-37
Testing engine piping for damage and looseness........................................................................... .30-37
Testing and adjusting air conditioner compressor belt tension........................................................ .30-38
Replacing alternator belt.................................................................................................................. .30-39
Power train............................................................................................................................................30-40
Testing oil leakage from axle final drive .......................................................................................... .30-40
Testing drive shaft for looseness, backlash, and damage............................................................... .30-41
Testing accelerator pedal................................................................................................................ .30-42
Testing and adjusting HST oil pressure........................................................................................... .30-44
Testing transfer clutch control pressure .......................................................................................... .30-49
Steering system ....................................................................................................................................30-50
Testing directional lever................................................................................................................... .30-50
Testing and adjusting steering wheel.............................................................................................. .30-51
Testing work equipment control lever.............................................................................................. .30-53
Testing and adjusting steering circuit oil pressure........................................................................... .30-54
Bleeding air from steering circuit..................................................................................................... .30-56
Brake system ...................................................................................................................................... .30-57
Testing brake pedal......................................................................................................................... .30-57
Testing and adjusting brake pedal and linkage............................................................................... .30-58
Testing braking performance........................................................................................................... .30-59
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00 Index and foreword
Index
WA200-7 00-5
Testing and adjusting accumulator charge pressure....................................................................... .30-60
Testing wheel brake oil pressure..................................................................................................... .30-62
Testing lowering of wheel brake pressure....................................................................................... .30-63
Testing wear of wheel brake disc.................................................................................................... .30-66
Bleeding air from wheel brake circuit .............................................................................................. .30-67
Releasing remaining pressure in brake accumulator circuit............................................................ .30-68
Testing parking brake performance................................................................................................. .30-69
Testing parking brake release pressure.......................................................................................... .30-70
Method of releasing parking brake manually................................................................................... .30-71
Hydraulic system...................................................................................................................................30-72
Testing and adjusting cooling fan speed......................................................................................... .30-72
Testing cooling fan pump circuit oil pressure....................................................................................30-73
Testing work equipment PPC oil pressure........................................................................................30-74
Testing and adjusting work equipment oil pressure..........................................................................30-75
Bleeding air from each part...............................................................................................................30-76
Releasing remaining pressure in hydraulic circuit.............................................................................30-77
Work equipment....................................................................................................................................30-78
Testing and adjusting bucket positioner............................................................................................30-78
Testing and adjusting boom kick-out switch......................................................................................30-79
Checking the proximity switch working pilot lamp.............................................................................30-80
Electrical system...................................................................................................................................30-81
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor................30-81
Special functions of machine monitor................................................................................................30-83
KOMTRAX terminal start-up procedure ..........................................................................................30-137
Lamp indication of KOMTRAX terminal...........................................................................................30-140
Handling voltage circuit of controller ...............................................................................................30-144
Test diodes...................................................................................................................................... 30-145
Pm Clinic.............................................................................................................................................30-146
Pm Clinic service............................................................................................................................. 30-146
40 Troubleshooting
Related information on troubleshooting..................................................................................................40-8
Points to remember when performing troubleshooting........................................................................40-8
How to proceed in troubleshooting....................................................................................................40-10
Checks before troubleshooting..........................................................................................................40-12
Check procedure before troubleshooting..........................................................................................40-14
Preparation for troubleshooting of electrical system .........................................................................40-32
Classification and procedures of troubleshooting..............................................................................40-37
Symptom and troubleshooting No.....................................................................................................40-41
Information described in troubleshooting table..................................................................................40-43
Procedure for troubleshooting of open circuit in wiring harness of pressure sensor system ............40-45
Connector list and layout...................................................................................................................40-48
Connection table of connector by No. of pins....................................................................................40-61
T-box and T-adapter list....................................................................................................................40-98
Fuse location table..........................................................................................................................40-102
Failure code list...............................................................................................................................40-105
Troubleshooting by failure code (Display of code).............................................................................. 40-113
Failure code [2F00MB] Malfunction of Parking Brake..................................................................... 40-113
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front).......................................................40-115
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....................................................... 40-117
Failure code [6091NX] HST Filter Clogging....................................................................................40-119
Failure code [7RHYKA] Open Circuit of Fan Motor EPC Solenoid Output...................................... 40-121
Failure code [7RHYKB] Ground Fault of Fan Motor EPC Solenoid Output.....................................40-123
Failure code [7RHYKY] Hot Short of Fan Motor EPC Solenoid Output ..........................................40-125
Failure code [989FN1] Travel Speed Overrun Alarm......................................................................40-127
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00 Index and foreword
Index
00-6 WA200-7
Failure code [AB00L6] Discharge of Alternator R Terminal.............................................................40-128
Failure code [AB00MA] Ground Fault or Open Circuit of Battery Relay Status Signal Line, or Insufficient
Battery Charging .......................................................................................................................40-130
Failure code [B@BAZG] Engine Oil Pressure Low .........................................................................40-132
Failure code [B@BCNS] Engine Water Overheat...........................................................................40-133
Failure code [B@BCZK] Engine Coolant Level Low .......................................................................40-134
Failure code [B@C6NS] Front Brake Oil Temperature Overheat (This Alarm)...............................40-136
Failure code [B@CRNS] HST Oil Temperature Overheat...............................................................40-137
Failure code [CA115] Eng Ne and Bkup Speed Sens Error............................................................40-138
Failure code [CA122] Charge Air Pressure Sensor High Error .......................................................40-139
Failure code [CA123] Charge Air Pressure Sensor Low Error........................................................40-141
Failure code [CA131] Throttle Sensor High Error............................................................................40-143
Failure code [CA132] Throttle Sensor Low Error.............................................................................40-145
Failure code [CA144] Coolant Temperature Sensor High Error......................................................40-147
Failure code [CA145] Coolant Temperature Sensor Low Error.......................................................40-149
Failure code [CA153] Charge Air Temperature Sensor High Error.................................................40-151
Failure code [CA154] Chg Air Temp Sensor Low Error...................................................................40-153
Failure code [CA187] Sensor 2 Supply Voltage Low Error..............................................................40-155
Failure code [CA221] Ambient Pressure Sensor High Error ...........................................................40-157
Failure code [CA222] Ambient Pressure Sensor Low Error............................................................40-159
Failure code [CA227] Sensor 2 Supply Voltage High Error.............................................................40-161
Failure code [CA234] Engine Overspeed........................................................................................40-162
Failure code [CA238] Ne Speed Sensor Supply Volt Error.............................................................40-163
Failure code [CA239] Ne Speed Sens Supply Volt High Error........................................................40-164
Failure code [CA271] IMV/PCV1 Short Error ..................................................................................40-165
Failure code [CA272] IMV/PCV1 Open Error..................................................................................40-167
Failure code [CA322] Injector #1 (L#1) Open/Short Error...............................................................40-169
Failure code [CA324] Injector #3 (L#3) Open/Short Error...............................................................40-171
Failure code [CA331] Injector #2 (L#2) Open/Short Error...............................................................40-173
Failure code [CA332] Injector #4 (L#4) Open/Short Error...............................................................40-175
Failure code [CA343] Engine Controller Internal Failure.................................................................40-177
Failure code [CA351] Injectors Drive Circuit Error...........................................................................40-178
Failure code [CA352] Sensor 1 Supply Voltage Low Error..............................................................40-179
Failure code [CA356] Mass Air Flow Sensor High Error .................................................................40-181
Failure code [CA357] Mass Air Flow Sensor Low Error..................................................................40-183
Failure code [CA386] Sensor 1 Supply Voltage High Error.............................................................40-185
Failure code [CA428] Water in Fuel Sensor High Error...................................................................40-186
Failure code [CA429] Water in Fuel Sensor Low Error ...................................................................40-188
Failure code [CA431] Idle Validation Sw Error................................................................................40-190
Failure code [CA432] Idle Validation Process Error........................................................................40-193
Failure code [CA435] Engine Oil Pressure Sw Error.......................................................................40-195
Failure code [CA441] Battery Voltage Low Error.............................................................................40-196
Failure code [CA442] Battery Voltage High Error............................................................................40-198
Failure code [CA449] Rail Press Very High Error............................................................................40-199
Failure code [CA451] Common Rail Pressure Sensor High Error...................................................40-200
Failure code [CA452] Common Rail Pressure Sensor Low Error....................................................40-202
Failure code [CA466] KVGT Motor Driver Position Error ................................................................40-204
Failure code [CA488] Chg Air Temp High Torque Derate...............................................................40-206
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error....................................................40-207
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error.....................................................40-209
Failure code [CA553] Common Rail Pressure High Error 1............................................................40-211
Failure code [CA555] Crankcase Press High Error 1......................................................................40-212
Failure code [CA556] Crankcase Press High Error 2......................................................................40-213
Failure code [CA559] Rail Press Low Error 1..................................................................................40-214
Failure code [CA689] Engine Ne Speed Sensor Error....................................................................40-217
Failure code [CA691] Intake Air Temp Sens High Error..................................................................40-219
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00 Index and foreword
Index
WA200-7 00-7
Failure code [CA692] Intake Air Temp Sens Low Error ..................................................................40-221
Failure code [CA697] ECM Internal Temperature Sensor High Error.............................................40-223
Failure code [CA698] EMC Internal Temperature Sensor Low Error..............................................40-224
Failure code [CA731] Engine Bkup Speed Sensor Phase Error.....................................................40-225
Failure code [CA778] Engine Bkup Speed Sensor Error ................................................................ 40-227
Failure code [CA1117] Persistent Data Lost Error.......................................................................... 40-232
Failure code [CA1695] Sensor 5 Supply Voltage High Error...........................................................40-233
Failure code [CA1696] Sensor 5 Supply Voltage Low Error ...........................................................40-234
Failure code [CA1843] Crankcase Press Sens High Error..............................................................40-235
Failure code [CA1844] Crankcase Press Sens Low Error ..............................................................40-237
Failure code [CA1896] EGR Valve Stuck Error............................................................................... 40-239
Failure code [CA1942] Crankcase Press Sens In-Range Error ......................................................40-240
Failure code [CA1961] EGR Motor Driver IC Over Temp Error ......................................................40-241
Failure code [CA2185] Throttle Sensor Supply Voltage High Error ................................................40-242
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error.................................................40-244
Failure code [CA2249] Rail Press Low Error 2................................................................................40-246
Failure code [CA2272] EGR Valve Position Sensor Low Error....................................................... 40-247
Failure code [CA2311] IMV Solenoid Error.....................................................................................40-249
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error.....................................................40-250
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error..................................................... 40-252
Failure code [CA2357] EGR Valve Servo Error ..............................................................................40-254
Failure code [CA2373] Exhaust Manifold Pressure Sensor High Error........................................... 40-255
Failure code [CA2374] Exhaust Manifold Pressure Sensor Low Error............................................40-257
Failure code [CA2375] EGR Orifice Temperature Sensor High Error.............................................40-259
Failure code [CA2376] EGR Orifice Temperature Sensor Low Error.............................................. 40-261
Failure code [CA2554] Exhaust Manifold Pressure Sensor In-Range Error ................................... 40-263
Failure code [CA2555] Grid Heater Relay Voltage Low Error......................................................... 40-264
Failure code [CA2556] Grid Heater Relay Voltage High Error........................................................40-266
Failure code [CA2961] EGR Orifice Temperature High Error 1 ......................................................40-268
Failure code [CA2973] Charge Air Pressure Sensor In-Range Error..............................................40-269
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error.................................................40-270
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error .................................................40-272
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error ................................................40-274
Failure code [CA3741] Common Rail Pressure Valve Trip Error.................................................... 40-276
Failure code [CA3918] KVGT Stuck Error.......................................................................................40-277
Failure code [CA3919] KVGT Motor Driver IC Over Temperature Error.........................................40-278
Failure code [CA3921] KVGT Servo Error 2 ................................................................................... 40-279
Failure code [CA3922] KVGT Motor Driver Open Error..................................................................40-280
Failure code [CA3923] KVGT Motor Driver Short Error .................................................................. 40-282
Failure code [D110L4] Disconnection or Short to Ground of Battery Relay Signal Line.................40-284
Failure code [D160KA] Disconnection of Backup Lamp Relay Output............................................40-286
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output.............................................40-288
Failure code [D160KY] Hot Short of Backup Lamp Relay Output................................................... 40-290
Failure code [D191KA] Disconnection of Neutral Output Relay......................................................40-292
Failure code [D191KB] Ground Fault of Neutral Output Relay........................................................ 40-294
Failure code [D191KY] Hot Short of Neutral Output Relay .............................................................40-296
Failure code [D192KA] Disconnection of ECSS Solenoid Relay.....................................................40-298
Failure code [D192KB] Ground Fault of ECSS Solenoid Relay...................................................... 40-300
Failure code [D192KY] Hot Short of ECSS Solenoid Relay............................................................40-302
Failure code [D1B0KA] Disconnection of HST Safety Relay...........................................................40-304
Failure code [D1B0KB] Ground Fault of HST Safety Relay............................................................ 40-306
Failure code [D1B0KY] Hot Short of HST Safety Relay..................................................................40-308
Failure code [D1B0MC] Malfunction of HST Safety Relay..............................................................40-310
Failure code [D1E6KA] Disconnection of Parking Brake Relay ......................................................40-311
Failure code [D1E6KB] Ground Fault of Parking Brake Relay........................................................40-313
Failure code [D1E6KY] Hot Short of Parking Brake Relay..............................................................40-315
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00 Index and foreword
Index
00-8 WA200-7
Failure code [D5ZHKA] Failure of Key SW C Signal.......................................................................40-317
Failure code [D5ZHKB] Key SW C Signal Hot Short Circuit............................................................40-319
Failure code [D5ZHL6] Disconnection of Key SW C.......................................................................40-321
Failure code [DAF3KK] Controller Power Source Low (MON)........................................................40-323
Failure code [DAF5KP] 5 V Sensor Power Supply: Ground Fault...................................................40-325
Failure code [DAF6KP] 24 V Sensor Power Supply: Ground Fault.................................................40-327
Failure code [DAFRKR] Machine Monitor CAN2 Communication Error (Machine Monitor)............40-329
Failure code [DAJ0KK] Controller Power Source Low (HST)..........................................................40-330
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST)................................................40-333
Failure code [DAJ0MC] HST Controller Malfunction.......................................................................40-334
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) .......................................................40-335
Failure code [DAJ2KK] Solenoid Power Source Low (HST) ...........................................................40-337
Failure code [DAJ4KB] Ground Fault of Solenoid Self-Holding Relay (HST)..................................40-340
Failure code [DAJ4KZ] Failure of Solenoid Self-Holding Relay (HST)............................................40-342
Failure code [DAJ5KX] Failure of 5 V Power Source 0 (HST).........................................................40-344
Failure code [DAJ6KX] Failure of 5 V Power Source 1 (HST).........................................................40-346
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST)....................................................40-348
Failure code [DAJLKA] Operating Lamp Open Circuit (HST)..........................................................40-349
Failure code [DAJLKB] Operating Lamp Short Circuit (HST)..........................................................40-351
Failure code [DAJQKR] CAN2 Disconnection (HST) ......................................................................40-353
Failure code [DAJRMA] Inconsistency of Option Selection (HST)..................................................40-354
Failure code [DB2QKR] CAN2 Disconnection (Engine Controller)..................................................40-355
Failure code [DB2RKR] CAN1 Disconnection (Engine Controller)..................................................40-359
Failure code [DBE6KX] 24V Output Power Supply System Failure................................................40-362
Failure code [DD1NL4] Fan Auto Reverse Switch Signal Error ......................................................40-364
Failure code [DD1NLD] Fan Reverse Switch Signal: Abnormal......................................................40-366
Failure code [DDB6L4] Parking Brake Signal Malfunction..............................................................40-368
Failure code [DDD7KA] Failure of Variable Speed Control.............................................................40-370
Failure code [DDD7KY] Hot Short of Variable Speed Control.........................................................40-372
Failure code [DDE5MA] Disconnection of Steering Oil Pressure Switch (Emergency Steering Control
Switch).......................................................................................................................................40-374
Failure code [DDK3KA] FNR SW Input Signal Disconnection.........................................................40-376
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ...........................................................40-378
Failure code [DDK6KA] FNR Lever Input Signal Disconnection .....................................................40-380
Failure code [DDK6KY] FNR Lever Input Signal Disconnection (Hot Short)...................................40-382
Failure code [DDNRLD] Ground Fault of Work Equipment Lock Switch.........................................40-384
Failure code [DDS5L6] Low Steering Oil Pressure (Emergency Steering Control).........................40-386
Failure code [DF10KA] Disconnection of Speed Range Input Switch.............................................40-388
Failure code [DF10KB] Disconnection of Speed Range Selector Switch (Hot Short).....................40-393
Failure code [DGH1KX] HST Oil Temperature Sensor Short to Ground.........................................40-398
Failure code [DGR2KB] Ground Fault of Brake Oil Temperature Sensor.......................................40-400
Failure code [DGR2KZ] Failure of Brake Oil Temperature Sensor .................................................40-402
Failure code [DHH1KX] Failure of HST Oil Pressure Sensor..........................................................40-404
Failure code [DHH1KY] Hot Short of HST Oil Pressure Sensor......................................................40-406
Failure code [DHPCKX] Failure of Boom Pressure Sensor (Bottom)..............................................40-408
Failure code [DHPDKX] Failure of Boom Pressure Sensor (Head).................................................40-410
Failure code [DHTCL6] HST Oil Filter Clogging Detection Failure..................................................40-412
Failure code [DJF1KA] Disconnection or Hot Short Circuit of Fuel Level Sensor...........................40-414
Failure code [DK5DKA] Failure of 3rd Lever Potentiometer Sensor (Main)....................................40-416
Failure code [DK5DKY] Hot Short of 3rd Lever Potentiometer Sensor (Main)................................40-419
Failure code [DK5DL8] 3rd Lever Potentiometer Sensor (Main & Sub) Disagree...........................40-421
Failure code [DK5EKA] Failure of 3rd Lever Potentiometer Sensor (Sub)......................................40-424
Failure code [DK5EKY] Hot Short of 3rd Lever Potentiometer Sensor (Sub)..................................40-427
Failure code [DKA0KX] Failure of Boom Angle Sensor...................................................................40-429
Failure code [DLM3KA] Failure of Cooling Fan Speed Sensor.......................................................40-431
Failure code [DLM3LC] Ground Fault of Cooling Fan Speed Sensor .............................................40-433
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00 Index and foreword
Index
WA200-7 00-9
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) .................................................. 40-434
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) .................................................. 40-436
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B)........................................................ 40-438
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) ...................................................... 40-441
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indicator..............................................40-443
Failure code [DV00KY] Hot Short of Alarm Buzzer......................................................................... 40-445
Failure code [DW26KA] Open Circuit of Motor 2 Solenoid..............................................................40-447
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid.............................................................40-449
Failure code [DW26KY] Hot Short of Motor 2 Solenoid ..................................................................40-451
Failure code [DW44KA] Open Circuit of Directional Pressure Selection Solenoid..........................40-453
Failure code [DW44KB] Ground Fault of Directional Pressure Selection Solenoid......................... 40-455
Failure code [DW44KY] Hot Short of Directional Pressure Selection Solenoid ..............................40-457
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid..................................................40-459
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid....................................................40-461
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ......................................................... 40-463
Failure code [DX19KA] Disconnection of Motor 1 Solenoid............................................................40-465
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid..............................................................40-468
Failure code [DX19KY] Hot Short of Motor 1 Solenoid ...................................................................40-470
Failure code [DX20KA] Disconnection of Clutch EPC Solenoid......................................................40-472
Failure code [DX20KB] Ground Fault of Clutch EPC Solenoid....................................................... 40-475
Failure code [DX20KY] Hot Short of Clutch EPC Solenoid............................................................. 40-477
Failure code [DXH7KA] Disconnection of Reverse Solenoid..........................................................40-479
Failure code [DXH7KB] Ground Fault of Reverse Solenoid............................................................40-481
Failure code [DXH7KY] Hot Short of Reverse Solenoid..................................................................40-483
Failure code [DXH8KA] Disconnection of Forward Solenoid ..........................................................40-484
Failure code [DXH8KB] Ground Fault of Forward Solenoid............................................................ 40-486
Failure code [DXH8KY] Hot Short of Forward Solenoid..................................................................40-488
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)................................................40-489
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) .................................................40-491
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .......................................................40-493
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)...............................................40-494
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)................................................. 40-496
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ......................................................40-498
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ........................................................40-499
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal....................................................40-502
Failure code [J141N1] Steering Pump Over Run............................................................................ 40-504
Failure code [LA00L3] Failure of Fan Reverse................................................................................40-505
Failure code [M100N1] HST Pump Over Run.................................................................................40-506
Failure code [M400N1] HST Motor 1 Over Run..............................................................................40-507
Troubleshooting of electrical system (E-mode)................................................................................... 40-508
E-1 Engine does not start................................................................................................................40-508
E-2 Manual preheating system does not work................................................................................40-513
E-3 Automatic preheating system does not work............................................................................40-516
E-4 While preheating is working, preheating monitor does not light up ..........................................40-518
E-5 When starting switch is turned to ON position, nothing is displayed on machine monitor........40-520
E-6 Travel speed is slow.................................................................................................................40-523
E-7 ECSS does not operate............................................................................................................40-525
E-8 ECSS remains being operated.................................................................................................40-528
E-9 Boom kick-out does not work or is not reset.............................................................................40-531
E-10 Bucket positioner does not work or is not reset......................................................................40-534
E-11 Boom FLOAT holding does not work or is not reset............................................................... 40-537
E-12 Directional selection does not work normally..........................................................................40-540
E-13 Fan does not rotate in reverse................................................................................................40-551
E-14 Fan remains in reverse rotation mode....................................................................................40-554
E-15 Wipers do not operate ............................................................................................................40-556
E-16 Window washer does not operate .......................................................................................... 40-561
00 Index and foreword
Index
00-10 WA200-7
E-17 Headlamp, clearance lamp, tail lamp or license-plate lamp does not light up or does not go out
..................................................................................................................................................40-564
E-18 Working lamp does not light up or does not go out.................................................................40-573
E-19 Turn signal and hazard lamp do not light up or do not go out.................................................40-578
E-20 Stop lamp does not light up or remains lighting up.................................................................40-585
E-21 Backup lamp does not light up or remains lighting up ............................................................40-588
E-22 Backup alarm does not sound or does not stop sounding......................................................40-591
E-23 Horn does not sound or does not stop sounding....................................................................40-593
E-24 Alarm buzzer does not sound or does not stop sounding.......................................................40-596
E-25 KOMTRAX system does not operate normally.......................................................................40-598
E-26 Fuel gauge does not indicate correct level .............................................................................40-600
E-27 Seat belt caution lamp indication is incorrect..........................................................................40-602
Troubleshooting for hydraulic and mechanical system (H-mode).......................................................40-603
Information described in troubleshooting table (H-mode)................................................................40-603
System chart of hydraulic and mechanical systems........................................................................40-604
Failure mode and cause table.........................................................................................................40-606
H-1 Machine travels neither forward nor in reverse.........................................................................40-612
H-2 Machine does not travel forward (normally travels in reverse).................................................40-614
H-3 Machine does not travel in reverse (normally travels forward).................................................40-615
H-4 Both forward and reverse travel speeds are low ......................................................................40-616
H-5 Forward travel speed is low (normal when traveling in reverse)...............................................40-618
H-6 Reverse travel speed is low (normal when traveling forward)..................................................40-619
H-7 Machine lacks power when traveling both forward and in reverse...........................................40-620
H-8 Machine lacks power when traveling forward (normal when traveling in reverse)....................40-622
H-9 Machine lacks power when traveling in reverse (normal when traveling forward)....................40-623
H-10 Engine stalls during travel or engine speed drops significantly..............................................40-624
H-11 Machine does not turn............................................................................................................40-625
H-12 Steering wheel is heavy to turn...............................................................................................40-627
H-13 Machine sways or large shocks are made while machine turns.............................................40-628
H-14 Machine turns to either side unintentionally during traveling..................................................40-629
H-15 Brake does not work or it is weak...........................................................................................40-630
H-16 Brake is not released or drags................................................................................................40-631
H-17 Parking brake does not work or it is weak..............................................................................40-632
H-18 Parking brake is not released or drags...................................................................................40-633
H-19 Boom does not rise.................................................................................................................40-634
H-20 Boom moves slow or lacks lifting force...................................................................................40-635
H-21 Boom rising speed lowers at certain height............................................................................40-636
H-22 Lift cylinder cannot hold down bucket (bucket rises off ground).............................................40-637
H-23 Hydraulic drift of boom is large...............................................................................................40-638
H-24 Boom wobbles during operation.............................................................................................40-642
H-25 Bucket does not tilt back.........................................................................................................40-643
H-26 Bucket moves slow or lacks tilting back force.........................................................................40-644
H-27 Bucket speed lowers in tilt-back motion..................................................................................40-645
H-28 Bucket cylinder cannot hold down bucket (bucket rises off ground).......................................40-646
H-29 Hydraulic drift of bucket is large..............................................................................................40-647
H-30 Loaded bucket wobbles during travel (with work equipment valve at "HOLD")......................40-648
H-31 Boom and bucket control levers do not move smoothly and are heavy to move....................40-649
H-32 Engine speed lowers remarkably or engine stalls while work equipment is operated............40-650
H-33 Large shock is made when work equipment starts and stops................................................40-651
H-34 When certain work equipment is relieved hydraulically, other work equipment moves..........40-652
H-35 ECSS does not operate and machine pitches and bounds....................................................40-653
H-36 Fan speed is abnormal (too high or low, or fan does not rotate)............................................40-654
H-37 Unusual noise is heard from around fan.................................................................................40-656
Troubleshooting of engine (S-mode)...................................................................................................40-657
Information mentioned in troubleshooting table (S mode)...............................................................40-657
S-1 Engine does not crank when starting switch is turned to START position................................40-658
00 Index and foreword
Index
WA200-7 00-11
S-2 Engine cranks but no exhaust smoke comes out.....................................................................40-659
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .40-660
S-4 Engine startability is poor.......................................................................................................... 40-661
S-5 Engine does not pick up smoothly............................................................................................40-663
S-6 Engine stops during operation..................................................................................................40-665
S-7 Engine runs rough or is unstable..............................................................................................40-666
S-8 Engine lacks power................................................................................................................... 40-667
S-9 Exhaust smoke is black............................................................................................................40-669
S-10 Engine oil consumption is excessive ...................................................................................... 40-671
S-11 Oil becomes contaminated quickly......................................................................................... 40-672
S-12 Fuel consumption is excessive...............................................................................................40-673
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)..............................................40-674
S-14 Oil pressure drops ..................................................................................................................40-675
S-15 Fuel mixes into engine oil.......................................................................................................40-676
S-16 Water mixes into engine oil (milky).........................................................................................40-677
S-17 Coolant temperature rises too high (overheating) ..................................................................40-678
S-18 Unusual noise is heard...........................................................................................................40-679
S-19 Vibration is excessive............................................................................................................. 40-680
S-20 Air cannot be bled from fuel circuit .........................................................................................40-681
50 Disassembly and assembly
General information on disassembly and assembly ...............................................................................50-4
How to read this manual......................................................................................................................50-4
Coating materials list...........................................................................................................................50-6
Special tool list ..................................................................................................................................50-10
Sketches of special tools...................................................................................................................50-14
Engine and cooling system...................................................................................................................50-24
Removal and installation of fuel supply pump assembly...................................................................50-24
Removal and installation of fuel injector assembly............................................................................50-28
Removal and installation of engine hood assembly..........................................................................50-36
Removal and installation of cylinder head assembly.........................................................................50-39
Removal and installation of radiator assembly..................................................................................50-50
Removal and installation of air aftercooler assembly........................................................................50-53
Removal and installation of hydraulic oil cooler assembly................................................................50-55
Removal and installation of engine assembly ...................................................................................50-57
Removal and installation of belt for alternator and air conditioner compressor.................................50-62
Removal and installation of engine front oil seal assembly...............................................................50-64
Removal and installation of engine rear oil seal assembly................................................................50-68
Removal and installation of cooling fan and fan motor assembly .....................................................50-72
Removal and installation of fuel tank assembly ................................................................................50-75
Removal and installation of KCCV ventilator assembly ....................................................................50-77
Removal and installation of KDOC muffler........................................................................................50-78
Removal and installation of EGR cooler assembly ...........................................................................50-79
Removal and installation of EGR valve assembly.............................................................................50-81
Power train............................................................................................................................................50-83
Removal and installation of transfer assembly..................................................................................50-83
Disassembly and assembly of transfer assembly .............................................................................50-87
Removal and installation of parking brake assembly...................................................................... 50-110
Removal and installation of parking brake cylinder assembly.........................................................50-112
Disassembly and assembly of parking brake assembly..................................................................50-113
Removal and installation of front axle assembly.............................................................................50-119
Removal and installation of rear axle assembly..............................................................................50-121
Disassembly and assembly of axle housing assembly ...................................................................50-124
Disassembly and assembly of differential assembly....................................................................... 50-133
00 Index and foreword
Index
00-12 WA200-7
Undercarriage and frame....................................................................................................................50-158
Removal and installation of center hinge pin...................................................................................50-158
Removal and installation of counterweight assembly......................................................................50-167
Hydraulic system.................................................................................................................................50-170
Removal and installation of HST pump and quadruple type gear pump assembly.........................50-170
Removal and installation of HST motor 1 assembly........................................................................50-174
Removal and installation of HST motor 2 assembly........................................................................50-176
Removal and installation of work equipment control valve assembly..............................................50-179
Removal and installation of ECSS (Electronically Controlled Suspension System) valve assembly
..................................................................................................................................................50-181
Removal and installation of hydraulic tank assembly......................................................................50-183
Disassembly and assembly of hydraulic cylinder assembly............................................................50-185
Work equipment..................................................................................................................................50-189
Removal and installation of work equipment assembly...................................................................50-189
Cab and its attachments .....................................................................................................................50-195
Removal and installation of operator's cab and floor frame assembly............................................50-195
Removal and installation of operator's cab glass (adhered glass) ..................................................50-200
Disassembly and assembly of operator's seat ................................................................................50-208
Removal and installation of air conditioner unit assembly...............................................................50-218
Removal and installation of air conditioner compressor assembly..................................................50-224
Electrical system.................................................................................................................................50-226
Removal and installation of machine monitor..................................................................................50-226
Removal and installation of engine controller assembly..................................................................50-228
Removal and installation of HST controller assembly.....................................................................50-230
Removal and installation of KOMTRAX terminal assembly.............................................................50-231
60 Maintenance standard
Engine and cooling system.................................................................................................................... 60-3
Engine mount and transfer mount...................................................................................................... 60-3
Damper............................................................................................................................................... 60-4
Cooling system................................................................................................................................... 60-5
Cooling fan motor............................................................................................................................... 60-6
Power train............................................................................................................................................. 60-8
Drive shaft .......................................................................................................................................... 60-8
Transfer........................................................................................................................................... 60-9
Axle.................................................................................................................................................. 60-17
Differential ....................................................................................................................................... 60-19
Limited slip differential..................................................................................................................... 60-23
Final drive........................................................................................................................................ 60-25
Steering system .................................................................................................................................. 60-28
Orbitrol valve ................................................................................................................................... 60-28
Steering cylinder.............................................................................................................................. 60-29
Steering column............................................................................................................................... 60-31
Priority valve.................................................................................................................................... 60-32
Emergency steering valve............................................................................................................... 60-33
Brake system ...................................................................................................................................... 60-34
Charge valve ................................................................................................................................... 60-34
Slack adjuster.................................................................................................................................. 60-36
Brake............................................................................................................................................... 60-37
Parking brake .................................................................................................................................. 60-39
Undercarriage and frame.................................................................................................................... 60-40
Axle mount and center hinge pin..................................................................................................... 60-40
Hydraulic system................................................................................................................................. 60-44
Hydraulic tank.................................................................................................................................. 60-44
Work equipment control valve......................................................................................................... 60-45
00 Index and foreword
Index
WA200-7 00-13
PPC valve........................................................................................................................................ 60-51
ECSS valve..................................................................................................................................... 60-54
Quadruple gear pump ..................................................................................................................... 60-55
Work equipment.................................................................................................................................. 60-57
Work equipment linkage.................................................................................................................. 60-57
Bucket ............................................................................................................................................. 60-59
Bucket positioner and boom kick-out .............................................................................................. 60-60
Work equipment cylinder................................................................................................................. 60-61
80 Appendix
Air conditioner.........................................................................................................................................80-3
Precautions for refrigerant...................................................................................................................80-3
Air conditioner component...................................................................................................................80-4
Configuration and function of refrigeration cycle.................................................................................80-6
Outline of refrigeration cycle................................................................................................................80-7
Air conditioner unit...............................................................................................................................80-9
Functions of main components in air conditioner unit .......................................................................80-10
Blower and intake unit.......................................................................................................................80-11
Compressor.......................................................................................................................................80-12
Condenser.........................................................................................................................................80-13
Receiver drier....................................................................................................................................80-14
Air conditioner control panel..............................................................................................................80-15
Procedure for troubleshooting...........................................................................................................80-16
Circuit diagram and arrangement of connector pins .........................................................................80-18
System diagram ................................................................................................................................80-20
Details of air conditioner unit.............................................................................................................80-22
Parts and connectors layout..............................................................................................................80-23
Inspection by self-diagnosis function (displays diagnosis on the control panel) ...............................80-25
Testing temperature control system..................................................................................................80-26
Testing FRESH/RECIRC air changeover..........................................................................................80-27
Testing evaporator temperature sensor............................................................................................80-29
Testing relays....................................................................................................................................80-30
Troubleshooting chart 1.....................................................................................................................80-31
Troubleshooting chart 2.....................................................................................................................80-33
Information described in troubleshooting table..................................................................................80-36
Troubleshooting for power supply system (Air conditioner does not operate) ..................................80-37
Troubleshooting for compressor and refrigerant system (Air is not cooled)......................................80-41
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......................80-44
Troubleshooting for temperature control...........................................................................................80-47
Troubleshooting for FRESH/RECIRC air changeover.......................................................................80-50
Connection of service tool.................................................................................................................80-52
Troubleshooting by gauge pressure..................................................................................................80-54
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit.................80-57
Handling of compressor oil................................................................................................................80-59
90 Diagrams and drawings
Hydraulic diagrams and drawings...........................................................................................................90-3
Symbols used in hydraulic circuit diagrams ........................................................................................90-3
Hydraulic circuit diagram.....................................................................................................................90-5
Electrical diagrams and drawings...........................................................................................................90-7
Symbols used in electric circuit diagrams ...........................................................................................90-7
Electrical circuit diagram ................................................................................................................ 90-11
Index........................................................................................................................................................... 1
00 Index and foreword
Important safety notice
00-14 WA200-7
Foreword, safety and general information
Important safety notice
qAppropriate servicing and repair are extremely important to ensure safe operation of the machine.
Theshop manual describes the effective and safe servicing and repair methods recommended by Komat-
su.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
qThe symbol mark kis used for such matters that require special cautions during the work. The work in-
dicated by the caution mark should be performed according to the instructions with special attention to the
cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe first
and take every necessary measure.
General precautions
kInappropriate handling causes an extreme
danger. Read and understand what is de-
scribed in the operation and maintenance
manual before operating the machine. Read
and understand what is described in this
manual before starting the work.
qBefore performing any greasing or repairs, read
all the safety labels stuck to the machine. For the
locations of the safety labels and detailed expla-
nation of precautions, see the operation and
maintenance manual.
qLocate a place in the repair workshop to keep
the tools and removed parts. Always keep the
tools and parts in their correct places. Always
keep the work area clean and make sure that
there is no dirt, water or oil on the floor. Smoke
only in the areas provided for smoking. Never
smoke while working.
qWhen performing any work, always wear the
safety shoes and helmet. Do not wear loose
work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when
hitting parts with a hammer.
2. Always wear the protective eyeglasses when
grinding parts with a grinder, etc.
qWhen performing any work with 2 or more work-
ers, always agree on the working procedure be-
fore starting. While working, always keep
conversations of the work between your fellow
workers and your self on any step of the work.
During the work, hang the warning tag of "UN-
DER WORKING" in the operator's compartment.
qOnly qualified workers must perform the work
and operation which require license or qualifica-
tion.
qKeep the tools in good condition. And learn the
correct way to use the tools, and use the proper
ones among them. Before starting the work,
thoroughly check the tools, lift truck, service ve-
hicle, etc.
qIf welding repairs is required, always have a
trained and experienced welder with good
knowledge of welding perform the work. When
performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
qBefore starting work, warm up your body thor-
oughly to start work under good condition.
qAvoid continuing work for long hours and take
rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
place.
Preparation
qBefore adding oil or making any repairs, place
the machine on a firm and level ground, and ap-
ply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
qBefore starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it is
not possible to lower the equipment to the
ground, insert the lock pin or use blocks to pre-
vent the work equipment from falling. And be
sure to lock all the work equipment control levers
and hang a warning tag on them.
qWhen performing the disassembling or assem-
bling work, support the machine securely with
blocks, jacks, or stands before starting the work.
(Rev. 2012/10)
Safety points
1 Good arrangement
2 Correct work clothes
3 Observance of work standard
4 Practice of making and checking signals
5Prohibition of operation and handling by unli-
censed workers
6 Safety check before starting work
7Wearing protective goggles (for cleaning or grind-
ing work)
8Wearing shielding goggles and protectors (for
welding work)
9 Good physical condition and preparation
10 Precautions against work which you are not used
to or you are used to too much
00 Index and foreword
Important safety notice
WA200-7 00-15
qRemove all of mud and oil from the steps or oth-
er places used to get on and off the machine
completely. Always use the handrails, ladders of
steps when getting on or off the machine. Never
jump on or off the machine. When the scaffold is
not provided, use steps or stepladder to secure
your footing.
Precautions during work
qFor the machine equipped with the battery dis-
connect switch, check that the system operating
lamp is turned off before starting the work. Then,
turn the battery disconnect switch to OFF (Q) po-
sition and remove the switch key. For the ma-
chine not equipped with the battery disconnect
switch, remove the cable from the battery before
starting the work. Be sure to remove the nega-
tive end (-) of the battery cable first.
qRelease the remaining pressure in the circuits
completely before the work when the parts in the
circuits of oil, fuel, coolant and air are discon-
nected or removed. When the cap of the oil filter,
drain plug or oil pressure pickup plug is re-
moved, loose them slowly to prevent the oil from
spurting out.
qWhen removing or installing the checking plug or
the piping in the fuel circuit, wait 30 seconds or
longer after the engine is shut down and start the
work after the remaining pressure is released
from the fuel circuit.
qImmediately after the engine is shut down, the
coolant and oil in the circuits are hot. Be careful
not to get scalded by the hot coolant and oil.
Start the work after checking that the coolant and
oil are cooled down sufficiently.
qStart the work after the engine is shut down. Be
sure to shut down the engine when working on or
around the rotating parts in particular. When
checking the machine without shutting down the
engine (measuring oil pressure, rotational
speed, oil or coolant temperature), take extreme
care not to get caught in the rotating parts or the
working equipment.
qThe hoist or crane must be used to sling the
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the
slings with ample capacity and install them to the
proper places. Operate the hoist or crane slowly
to prevent the component from hitting any other
part. Do not work with any part still raised by the
hoist or crane.
qWhen removing the part which is under internal
pressure or reaction force of the spring, always
leave 2 bolts in diagonal positions. Loosen those
2 bolts gradually and alternately and release the
pressure, then, remove the part.
qWhen removing the part, be careful not to break
or damage the electrical wiring. The damaged
wiring may cause electrical fires.
qWhen removing piping, prevent the fuel or oil
from spilling out. If any fuel or oil drips onto the
floor, wipe it off immediately. Fuel or oil on the
floor can cause you to slip and can even cause
fires.
qAs a general rule, do not use gasoline to wash
parts. Do not use gasoline to clean the electrical
parts, in particular.
qReinstall the parts removed to their original plac-
es. Replace the damaged parts and the parts
which must not be used with new ones.
When installing the hoses and wiring harnesses,
be careful that they are not damaged by contact-
ing with other parts when the machine is operat-
ed.
qWhen connecting the high pressure hoses and
tubes, make sure that they are not twisted. The
damaged high pressure hoses and tubes are
very dangerous when they are installed. So, be
extremely careful when connecting the high
pressure pipings. In addition, check that their
connections are correct.
qWhen assembling or installing the parts, be sure
to tighten the bolts to the specified torque. When
installing the protective parts such as guards, or
the parts which vibrate violently or rotate at high
speeds, be sure to check that they are installed
correctly.
qWhen aligning 2 holes, never insert your fingers
or hand into the holes. Align the holes with care
so that your fingers are not caught in the hole.
qWhen measuring hydraulic pressure, check that
the measuring tools are correctly installed.
qPay attention to safety when removing and in-
stalling the tracks of the track type machines.
When removing the track, it separates suddenly.
The workers should not stand at either end of the
track.
qIf the engine is operated for a long time in a
closed place which is not ventilated well, you
may suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate the
place well.
00 Index and foreword
Important safety notice
00-16 WA200-7
Precautions for slinging work and making
signals
qOnly one appointed worker must make signals
and co-worker must communicate with each oth-
er frequently. The appointed signaler must make
specified signals clearly at the place where the
signaler is well seen from the operator's seat and
where the signaler can see the working condition
easily. The signaler must always stand in front of
the load and guide the operator safely.
1. Do not stand under the load.
2. Do not step on the load.
qCheck the slings before starting sling work.
qKeep putting on the gloves during sling work.
(Put on the leather gloves, if available.)
qMeasure the weight of the load by the eye and
check its center of gravity.
qUse the proper sling according to the weight of
the load and method of slinging. If too thick wire
ropes are used to sling a light load, the load may
slip and fall.
qDo not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.
kSlinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
qHanging angle must be 60 deg. or smaller as a
rule.
qWhen hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower
than that of the hook.
aWhen slinging a load with 2 ropes or more,
the larger the hanging angle is, the larger the
tension of each rope. The figure bellow
shows the variation of allowable load in kg
when hoisting is made with 2 ropes, each of
which is allowed to sling up to 9.8 kN
{1,000kg} a load vertically, at various hang-
ing angles. When the 2 ropes sling a load
vertically, up to 2,000 kg of total weight can
be suspended. This weight is reduced to
1,000 kg when the 2 ropes make a hanging
angle of 120 deg.. If the 2 ropes sling a 2,000
kg load at a hanging angle of 150 deg., each
rope is subjected to a force as large as 4,000
kg.
qWhen installing wire ropes to an angular load,
apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.
qUse the specified eye bolts and fix wire ropes,
chains, etc. to them with shackles, etc.
qApply wire ropes to the middle part of the hook.
aSlinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
The strength of the hook is maximum at its
central part.
qDo not use twisted or kinked wire ropes.
qWhen slinging up a load, observe the following.
1. Wind up the rope slowly until the wire rope
tensions. When putting your hands on the
wire ropes, do not grasp them but press them
down from above. If you grasp them, your
fingers may be caught.
2. After the wire ropes are stretched, stop the
crane and check the condition of the slung
load, wire ropes, and pads.
3. If the load is unstable or the wire rope or
chains are twisted, lower the load and lift it up
again.
4. Do not lift up the load at an angle.
qWhen lowering a load, pay attention to the fol-
lowing.
1. When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
00 Index and foreword
Important safety notice
WA200-7 00-17
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane
aRead the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
Precautions for using overhead traveling crane
kThe hoist or crane must be used to sling the
components weighing 25 kg or heavier. A
part weighing 25 kg or heavier in "disassem-
bly and assembly" section is indicated with
the symbol of 4.
qBefore starting work, check the wire ropes,
brake, clutch, controller, rails, over winding pre-
vention device, ground fault circuit interrupter for
electric shock prevention, crane collision pre-
vention device, and energizing warning lamp,
and check the following safety items.
qObserve the signals for sling work.
qOperate the hoist at a safe place.
qBe sure to check the directions of the direction
indication plate (north, south, east and west) and
the operating button.
qDo not sling a load at an angle. Do not move the
crane while the slung load is swinging.
qDo not raise or lower a load while the crane is
moving longitudinally or laterally.
qDo not drag a sling.
qWhen lifting up a load, stop it just after it leaves
the ground and check safety, and then lift it up.
qConsider the travel route in advance and lift up a
load to a safe height.
qPlace the control switch in a position where it will
not be an obstacle to work and passage.
qAfter operating the hoist, do not swing the control
switch.
qRemember the position of the main switch so
that you can turn off the power immediately in an
emergency.
qShut down the main switch when the hoist stops
because of a blackout. When turning on a switch
which is turned OFF by the ground fault circuit in-
terrupter for electric shock prevention, check
that the devices related to that switch are not in
operating condition.
qIf you find an obstacle around the hoist, stop the
operation.
qAfter finishing the work, stop the hoist at the
specified position and raise the hook to at least
2 meters above the floor. Do not leave the sling
attached to the hook.
Selecting wire ropes
qSelect adequate ropes depending on the weight
of the parts to be hoisted, referring to the table
below
Wire rope (JIS G3525, 6 x 37 - Type A)
(Standard Z twist wire ropes without galvanizing)
aThe allowable load is calculated as one sixth of
the breaking load of the rope to be used (safety
coefficient: 6).
Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit
Disconnection
kWhen replacing the air conditioner unit, air
conditioner compressor, condenser or re-
ceiver drier, etc., collect the refrigerant (air
conditioner gas: R134a) from the air condi-
tioner circuit before disconnecting the air
conditioner hoses.
aAsk a qualified person for collecting, adding and
filling operations of the refrigerant (air condition-
er gas: R134a). (Only registered persons can
work.)
aNever release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
kIf refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or fill-
ing the air conditioner circuit with the refrig-
erant.
qWhen loosening the nuts fixing air conditioner
hoses and tubes, be sure to use 2 wrenches; use
one wrench to fix and use the other one to loos-
en the nut.
Nominaldiameter
of rope Allowable load
mm kN ton
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
00 Index and foreword
Important safety notice
00-18 WA200-7
Connection
qWhen installing the hose for the air conditioner
circuit, take care not to allow invasion of dirt,
dusts and water into the hose.
qCheck that the O-rings are fitted to the joints
when connecting the air conditioner piping.
qOnce an O-ring is used, it is deformed and dete-
riorated. Accordingly, do not reuse it.
qWhen removing the O-rings, use a soft tool so
that the piping is not damaged.
qCheck that the O-ring is not damaged or deterio-
rated.
qApply compressor oil for refrigerant (R134a) to
the O-ring.
aHowever, do not apply oil to the threaded part
of a bolt, nut or union.
qWhen tightening nuts of the air conditioner hos-
es and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
aExample of fitting of O-ring
qAn O-ring is fitted to every joint of the air con-
ditioner piping.
For tightening torques, see "Others", "Precau-
tions for disconnection and connection of air
conditioner piping".
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL
SYSTEMS ZXL100PG
(equivalent to PAG46)
SANDEN SP-10
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