50 Disassembly and assemblyRemoval and installation of engine front oil seal assembly

WA200-7 50-67

Installation1. Install engine front oil seal (24) by using tool A1.

a Check that end face corners and seal lipsliding surface of the crankshaft and thehousing are free from flaw, burr, or rustbefore installing the engine front oil seal.

a Degrease, clean and dry the seal contactsurface of the crankshaft and the seal lipsurface to prevent oil leakage beforeinstalling the engine front oil seal.

a Do not apply oil, grease, etc. to thecrankshaft and seal lip surface wheninstalling the engine front oil seal.

a Dimensions of engine font oil seal (24) mustbe in the following range from cover (25)

q Protrusion (x): Max. 0.38 mmq Facial runout (TIR: Total Indicator Reading)

(y): Max. 0.25 mm

2. Crankshaft pulley1) Install crankshaft pulley (22) while aligning its

dowel hole to the dowel pin of the crankshaft.2) Tighten mounting bolts (21) according to the

following procedure.1] Tighten the bolts to 55 ± 5 Nm {5.6 ± 0.5

kgm} in diagonal order.2] Tighten 180 degrees.3] Tighten the bolts to 55 ± 5 Nm {5.6 ± 0.5

kgm} in diagonal order.4] Retighten the bolts by 90 ± 5 degrees.

a Tool A6 (wrench) is available for angletightening. (See the tool table.)

a When an angle tightening tool is notused

5] After above steps 1] to 3] are finished, puta paint mark on the crankshaft pulley andmounting bolts.

6] Retighten the bolts by 90 ± 5 degrees.

q Perform subsequent installation in the reverseorder to removal.

50 Disassembly and assemblyRemoval and installation of engine rear oil seal assembly

50-68 WA200-7

Removal and installation of engine rear oil seal assemblySpecial tools

Removalk Place the machine on a level surface, and set

the lock bar to frames to lock front and rearframes.

k Lower the work equipment to the groundcompletely and stop the engine. Apply theparking brake and put the blocks under thewheels.

k Turn the battery disconnect switch to OFFposition, and remove the key. (For details,see Testing and adjusting, "Handling batterydisconnect switch".)

k If you drain the coolant when it is still hot,you may be scalded. Wait until the coolanttemperature drops before starting the work.

1. Loosen radiator drain plug (1a), and drain thecoolant.

6 Radiator: Approximately 24.6 l

2. Remove the engine hood assembly. For details,see "Removal and installation of engine hoodassembly".

3. Remove the engine assembly. For details, see"Removal and installation of engine assembly".

4. Remove 8 mounting bolts (1), and removedamper flange (2). [*1]

5. Install eyebolt [1] in the screw hole of dampermounting bolt, and sling flywheel assembly (4).

6. Remove 2 flywheel mounting bolts and installguide bolts [2].

7. Remove 6 remaining mounting bolts (3), andhoist and remove flywheel assembly (4). [*2]

4 Flywheel assembly: 57 kg

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50 Disassembly and assemblyRemoval and installation of engine rear oil seal assembly

WA200-7 50-69

8. Engine rear oil seal1) Install tool A2 to the crankshaft.2) Screw tapping screws [3] of tool A2 into the

seal carrier of engine rear oil seal (5).3) Turn the handle clockwise to remove engine

rear oil seal (5).

Installation1. Be sure to keep pilot [4] attached to engine rear

oil seal (5) until the seal is installed to thecrankshaft. a Check that end face corners and seal lip

sliding surface of the crankshaft and thehousing are free from flaw, burr, or rustbefore installing the engine rear oil seal.

a Degrease, clean and dry the seal contactsurface of the crankshaft and the seal lipsurface to prevent oil leakage beforeinstalling the engine rear oil seal.

a Do not apply oil, grease, etc. to thecrankshaft and seal lip surface wheninstalling the engine rear oil seal.

2. Install pilot [4] to crankshaft (6), and insertengine rear oil seal (5) into flywheel housing (7).

3. Push in engine rear oil seal (5) further, and thenremove pilot [4].

50 Disassembly and assemblyRemoval and installation of engine rear oil seal assembly

50-70 WA200-7

4. By using tool A2, install engine rear oil seal (5) toflywheel housing (7).a Push in engine rear oil seal (5) taking care

not to bend the seal.a Protrusion (x) of engine rear oil seal (5): Max.

0.38 mm

q Perform the subsequent installation in thereverse order to removal.

[*1]a Install damper flange (2) so that the direction of

(a) part is as shown in the following figure.

2 Damper flange mounting bolt (1):Adhesive (LT-2)

3 Damper flange mounting bolt (1):44.1 to 53.9 Nm {4.5 to 5.5 kgm}

[*2]a Tighten 8 flywheel assembly mounting bolts in

the order shown in the figure below.3 Flywheel mounting bolt:

137 ± 7 Nm {13.97 ± 0.71 kgm}

a Set tool A4, use wrench [5] to prevent theflywheel from rotating, and tighten flywheelmounting bolts.

50 Disassembly and assemblyRemoval and installation of engine rear oil seal assembly

WA200-7 50-71

q Measurement of radial runouta Radial runout: Max. 0.13 mm

1) Install dial gauge [6] on the stand, and set itto flywheel housing (7).

2) Apply the probe of dial gauge perpendicularto spigot joint part (b) or outer circumferenceof the flywheel.

3) Rotate the flywheel by 1 turn, and measurethe difference between the lowest and thehighest values the pointer of dial gaugepoints.a Rotate the flywheel 1 turn and check that

the dial gauge pointer is at the sameposition as it was located before therevolution.

q Measurement of facial runouta Facial runout: Max. 0.20 mm

1) Install dial gauge [6] on the stand, and set itto flywheel housing (7).

2) Apply the probe of dial gauge perpendicularto end face (c) of the flywheel at a point nearthe outer circumference.

3) Rotate the flywheel by 1 turn, and measurethe difference between the lowest and thehighest values the pointer of dial gaugepoints.

a Rotate the flywheel 1 turn and check that the dialgauge pointer is at the same position as it waslocated before the revolution.

q Air bleedingBleed air from the fuel circuit. For details, seeTesting and adjusting, "Bleeding air from fuelcircuit".

q Refilling with coolantRefill with coolant to the specified level throughthe coolant filler port. Run the engine to circulatethe coolant through the system. Then check thecoolant level again.

5 Total of coolant: Approximately 24.6 l (Fordetails, see "Table of fuel, coolant andlubricants".)

50 Disassembly and assemblyRemoval and installation of cooling fan and fan motor assembly

50-72 WA200-7

Removal and installation of cooling fan and fan motor assemblySpecial tools

Removalk Place the machine on a level surface, and set

the lock bar to frames to lock front and rearframes.

k Lower the work equipment to the groundcompletely and stop the engine. Apply theparking brake and put the blocks under thewheels.

k Turn the battery disconnect switch to OFFposition, and remove the key. (For details,see Testing and adjusting, "Handling batterydisconnect switch".)

1. Open radiator grille (1).

2. Remove cover (2).

3. Remove 4 clamps (3) of the fuel tank breatherhose.

4. Remove clip (4), and disconnect hose (5) frombreather (6).

5. Remove breather (6).

6. Remove 2 wiring harness clamps (7).

7. Disconnect wiring harness connectors R19 (8)and R29 (9).

8. Disconnect P port hose (10), TC port hose (11),T port hose (12), and PP port hose (13).a Plug the disconnected hoses and ports to

prevent oil from flowing out.

9. Remove 4 shroud mounting bolts (14). [*1]

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A 8 791-415-2002 Remover t 1

Cover00 Index and forewordIndex and forewordIndex

Foreword, safety and general informationImportant safety noticePrecautions to prevent fireAction if fire occursDispose of waste materials

How to read the shop manualExplanation of terms for maintenance standardHandling equipment of fuel system devicesHandling of intake system partsHandling of hydraulic equipmentMethod of disconnecting and connecting of push-pull type couplerHandling of electrical equipmentHow to read electric wire codePrecautions when performing operationPractical use of KOMTRAXStandard tightening torque tableList of AbbreviationConversion table

01 SpecificationsSpecificationsSpecification dimension drawingSpecificationsWeight tableTable of fuel, coolant, and lubricants

10 Structure and functionEngine and cooling systemVFTEGR system piping drawingEGR system circuit diagramEGR valveEGR coolerKCCV layout drawingKCCV ventilatorCDR valveForming of condensed water and emulsion

KDOC mufflerDamperCooling systemCooling system hydraulic piping diagramCooling fan motor

Power trainPower trainPower train system diagramDrive shaftHST hydraulic piping diagramHST pumpHST motorTransferClutch solenoid valveAxleDifferentialTorque proportioning differentialLimited slip differentialFinal drive

Steering systemSteering piping diagramOrbitrol valveSteering columnPriority valveEmergency steering valve

Brake systemBrake piping diagramBrake valveCharge valveAccumulator (for brake)Slack adjusterBrakeParking brake controlParking brakeParking brake cylinderParking brake solenoid valveInching valve

Undercarriage and frameAxle mount and center hinge pin

Hydraulic systemHydraulic component layoutWork equipment control lever linkageHydraulic tankAccumulator (for PPC circuit)Work equipment control valvePPC valveAttachment EPC valveWork equipment lock solenoid valveECSS valveAccumulator (for ECSS)2-way restrictor valveCushion valveAccumulator (for oil cooler circuit)Quadruple gear pumpQuick coupler solenoid valve

Work equipmentWork equipment linkageBucketBucket positioner and boom kick-out

Cab and its attachmentsCab

Electrical systemMachine monitor systemMachine monitorElectrical system (HST controller system)System component partsHST controllerECSSKOMTRAX systemEngine starting circuitEngine stopping circuitPreheating systemAutomatic preheating systemManual preheating systemEngine output limit functionAutomatic warm-up functionParking brake control systemMulti-function mono-leverSensor

20 Standard value tableStandard value tableStandard value table for engineStandard value table for machine

30 Testing and adjustingRelated information on testing and adjustingTools for testing and adjusting

Engine and cooling systemTesting and adjusting engine speedTesting exhaust gas temperatureTesting exhaust gas colorTesting and adjusting valve clearanceTesting compression pressureTesting blowby pressureTesting engine oil pressureTesting boost pressureHandling equipment of fuel system devicesReleasing remaining pressure from fuel systemTesting fuel pressureTesting fuel discharge, return and leakageBleeding air from fuel systemTesting fuel circuit for leakageHandling cylinder cutout mode operationHandling no-injection cranking operationTesting KDPF and muffler stack for looseness and damageTesting KDOC functionTesting installed condition of cylinder heads and manifoldsTesting engine piping for damage and loosenessTesting and adjusting air conditioner compressor belt tensionReplacing alternator belt

Power trainTesting oil leakage from axle final driveTesting drive shaft for looseness, backlash, and damageTesting accelerator pedalTesting and adjusting HST oil pressureTesting transfer clutch control pressure

Steering systemTesting directional leverTesting and adjusting steering wheelTesting work equipment control leverTesting and adjusting steering circuit oil pressureBleeding air from steering circuit

Brake systemTesting brake pedalTesting and adjusting brake pedal and linkageTesting braking performanceTesting and adjusting accumulator charge pressureTesting wheel brake oil pressureTesting lowering of wheel brake pressureTesting wear of wheel brake discBleeding air from wheel brake circuitReleasing remaining pressure in brake accumulator circuitTesting parking brake performanceTesting parking brake release pressureMethod of releasing parking brake manually

Hydraulic systemTesting and adjusting cooling fan speedTesting cooling fan pump circuit oil pressureTesting work equipment PPC oil pressureTesting and adjusting work equipment oil pressureBleeding air from each partReleasing remaining pressure in hydraulic circuit

Work equipmentTesting and adjusting bucket positionerTesting and adjusting boom kick-out switchChecking the proximity switch working pilot lamp

Electrical systemAdjusting replaced, reassembled or added sensor, controller, etc. with machine monitorSpecial functions of machine monitorKOMTRAX terminal start-up procedureLamp indication of KOMTRAX terminalHandling voltage circuit of controllerTest diodes

Pm ClinicPm Clinic service

40 TroubleshootingRelated information on troubleshootingPoints to remember when performing troubleshootingHow to proceed in troubleshootingChecks before troubleshootingCheck procedure before troubleshootingWalk-around checkCheck according to the check procedure

Preparation for troubleshooting of electrical systemClassification and procedures of troubleshootingSymptom and troubleshooting No.Information described in troubleshooting tableProcedure for troubleshooting of open circuit in wiring harness of pressure sensor systemConnector list and layoutConnection table of connector by No. of pinsT-box and T-adapter listFuse location tableFailure code list

Troubleshooting by failure code (Display of code)Failure code [2F00MB] Malfunction of Parking BrakeFailure code [2G42ZG] Accumulator Oil Pressure Low (Front)Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)Failure code [6091NX] HST Filter CloggingFailure code [7RHYKA] Open Circuit of Fan Motor EPC Solenoid OutputFailure code [7RHYKB] Ground Fault of Fan Motor EPC Solenoid OutputFailure code [7RHYKY] Hot Short of Fan Motor EPC Solenoid OutputFailure code [989FN1] Travel Speed Overrun AlarmFailure code [AB00L6] Discharge of Alternator R TerminalFailure code [AB00MA] Ground Fault or Open Circuit of Battery Relay Status Signal Line, or Insufficient Battery ChargingFailure code [B@BAZG] Engine Oil Pressure LowFailure code [B@BCNS] Engine Water OverheatFailure code [B@BCZK] Engine Coolant Level LowFailure code [B@C6NS] Front Brake Oil Temperature Overheat (This Alarm)Failure code [B@CRNS] HST Oil Temperature OverheatFailure code [CA115] Eng Ne and Bkup Speed Sens ErrorFailure code [CA122] Charge Air Pressure Sensor High ErrorFailure code [CA123] Charge Air Pressure Sensor Low ErrorFailure code [CA131] Throttle Sensor High ErrorFailure code [CA132] Throttle Sensor Low ErrorFailure code [CA144] Coolant Temperature Sensor High ErrorFailure code [CA145] Coolant Temperature Sensor Low ErrorFailure code [CA153] Charge Air Temperature Sensor High ErrorFailure code [CA154] Chg Air Temp Sensor Low ErrorFailure code [CA187] Sensor 2 Supply Voltage Low ErrorFailure code [CA221] Ambient Pressure Sensor High ErrorFailure code [CA222] Ambient Pressure Sensor Low ErrorFailure code [CA227] Sensor 2 Supply Voltage High ErrorFailure code [CA234] Engine OverspeedFailure code [CA238] Ne Speed Sensor Supply Volt ErrorFailure code [CA239] Ne Speed Sens Supply Volt High ErrorFailure code [CA271] IMV/PCV1 Short ErrorFailure code [CA272] IMV/PCV1 Open ErrorFailure code [CA322] Injector #1 (L#1) Open/Short ErrorFailure code [CA324] Injector #3 (L#3) Open/Short ErrorFailure code [CA331] Injector #2 (L#2) Open/Short ErrorFailure code [CA332] Injector #4 (L#4) Open/Short ErrorFailure code [CA343] Engine Controller Internal FailureFailure code [CA351] Injectors Drive Circuit ErrorFailure code [CA352] Sensor 1 Supply Voltage Low ErrorFailure code [CA356] Mass Air Flow Sensor High ErrorFailure code [CA357] Mass Air Flow Sensor Low ErrorFailure code [CA386] Sensor 1 Supply Voltage High ErrorFailure code [CA428] Water in Fuel Sensor High ErrorFailure code [CA429] Water in Fuel Sensor Low ErrorFailure code [CA431] Idle Validation Sw ErrorFailure code [CA432] Idle Validation Process ErrorFailure code [CA435] Engine Oil Pressure Sw ErrorFailure code [CA441] Battery Voltage Low ErrorFailure code [CA442] Battery Voltage High ErrorFailure code [CA449] Rail Press Very High ErrorFailure code [CA451] Common Rail Pressure Sensor High ErrorFailure code [CA452] Common Rail Pressure Sensor Low ErrorFailure code [CA466] KVGT Motor Driver Position ErrorFailure code [CA488] Chg Air Temp High Torque DerateFailure code [CA515] Rail Pressure Sensor Sup Volt High ErrorFailure code [CA516] Rail Pressure Sensor Sup Volt Low ErrorFailure code [CA553] Common Rail Pressure High Error 1Failure code [CA555] Crankcase Press High Error 1Failure code [CA556] Crankcase Press High Error 2Failure code [CA559] Rail Press Low Error 1Failure code [CA689] Engine Ne Speed Sensor ErrorFailure code [CA691] Intake Air Temp Sens High ErrorFailure code [CA692] Intake Air Temp Sens Low ErrorFailure code [CA697] ECM Internal Temperature Sensor High ErrorFailure code [CA698] EMC Internal Temperature Sensor Low ErrorFailure code [CA731] Engine Bkup Speed Sensor Phase ErrorFailure code [CA778] Engine Bkup Speed Sensor ErrorFailure code [CA1117] Persistent Data Lost ErrorFailure code [CA1695] Sensor 5 Supply Voltage High ErrorFailure code [CA1696] Sensor 5 Supply Voltage Low ErrorFailure code [CA1843] Crankcase Press Sens High ErrorFailure code [CA1844] Crankcase Press Sens Low ErrorFailure code [CA1896] EGR Valve Stuck ErrorFailure code [CA1942] Crankcase Press Sens In-Range ErrorFailure code [CA1961] EGR Motor Driver IC Over Temp ErrorFailure code [CA2185] Throttle Sensor Supply Voltage High ErrorFailure code [CA2186] Throttle Sensor Supply Voltage Low ErrorFailure code [CA2249] Rail Press Low Error 2Failure code [CA2272] EGR Valve Position Sensor Low ErrorFailure code [CA2311] IMV Solenoid ErrorFailure code [CA2349] EGR Valve Solenoid Open Circuit ErrorFailure code [CA2353] EGR Valve Solenoid Short Circuit ErrorFailure code [CA2357] EGR Valve Servo ErrorFailure code [CA2373] Exhaust Manifold Pressure Sensor High ErrorFailure code [CA2374] Exhaust Manifold Pressure Sensor Low ErrorFailure code [CA2375] EGR Orifice Temperature Sensor High ErrorFailure code [CA2376] EGR Orifice Temperature Sensor Low ErrorFailure code [CA2554] Exhaust Manifold Pressure Sensor In-Range ErrorFailure code [CA2555] Grid Heater Relay Voltage Low ErrorFailure code [CA2556] Grid Heater Relay Voltage High ErrorFailure code [CA2961] EGR Orifice Temperature High Error 1Failure code [CA2973] Charge Air Pressure Sensor In-Range ErrorFailure code [CA3419] Mass Air Flow Sensor Sup Volt High ErrorFailure code [CA3421] Mass Air Flow Sensor Sup Volt Low ErrorFailure code [CA3724] EGR/KVGT Motor Driver Power Low ErrorFailure code [CA3741] Common Rail Pressure Valve Trip ErrorFailure code [CA3918] KVGT Stuck ErrorFailure code [CA3919] KVGT Motor Driver IC Over Temperature ErrorFailure code [CA3921] KVGT Servo Error 2Failure code [CA3922] KVGT Motor Driver Open ErrorFailure code [CA3923] KVGT Motor Driver Short ErrorFailure code [D110L4] Disconnection or Short to Ground of Battery Relay Signal LineFailure code [D160KA] Disconnection of Backup Lamp Relay OutputFailure code [D160KB] Ground Fault of Backup Lamp Relay OutputFailure code [D160KY] Hot Short of Backup Lamp Relay OutputFailure code [D191KA] Disconnection of Neutral Output RelayFailure code [D191KB] Ground Fault of Neutral Output RelayFailure code [D191KY] Hot Short of Neutral Output RelayFailure code [D192KA] Disconnection of ECSS Solenoid RelayFailure code [D192KB] Ground Fault of ECSS Solenoid RelayFailure code [D192KY] Hot Short of ECSS Solenoid RelayFailure code [D1B0KA] Disconnection of HST Safety RelayFailure code [D1B0KB] Ground Fault of HST Safety RelayFailure code [D1B0KY] Hot Short of HST Safety RelayFailure code [D1B0MC] Malfunction of HST Safety RelayFailure code [D1E6KA] Disconnection of Parking Brake RelayFailure code [D1E6KB] Ground Fault of Parking Brake RelayFailure code [D1E6KY] Hot Short of Parking Brake RelayFailure code [D5ZHKA] Failure of Key SW C SignalFailure code [D5ZHKB] Key SW C Signal Hot Short CircuitFailure code [D5ZHL6] Disconnection of Key SW CFailure code [DAF3KK] Controller Power Source Low (MON)Failure code [DAF5KP] 5 V Sensor Power Supply: Ground FaultFailure code [DAF6KP] 24 V Sensor Power Supply: Ground FaultFailure code [DAFRKR] Machine Monitor CAN2 Communication Error (Machine Monitor)Failure code [DAJ0KK] Controller Power Source Low (HST)Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST)Failure code [DAJ0MC] HST Controller MalfunctionFailure code [DAJ1KA] Disconnection of Key SW ACC (HST)Failure code [DAJ2KK] Solenoid Power Source Low (HST)Failure code [DAJ4KB] Ground Fault of Solenoid Self-Holding Relay (HST)Failure code [DAJ4KZ] Failure of Solenoid Self-Holding Relay (HST)Failure code [DAJ5KX] Failure of 5 V Power Source 0 (HST)Failure code [DAJ6KX] Failure of 5 V Power Source 1 (HST)Failure code [DAJ9KQ] Inconsistency of Model Selection (HST)Failure code [DAJLKA] Operating Lamp Open Circuit (HST)Failure code [DAJLKB] Operating Lamp Short Circuit (HST)Failure code [DAJQKR] CAN2 Disconnection (HST)Failure code [DAJRMA] Inconsistency of Option Selection (HST)Failure code [DB2QKR] CAN2 Disconnection (Engine Controller)Failure code [DB2RKR] CAN1 Disconnection (Engine Controller)Failure code [DBE6KX] 24V Output Power Supply System FailureFailure code [DD1NL4] Fan Auto Reverse Switch Signal ErrorFailure code [DD1NLD] Fan Reverse Switch Signal: AbnormalFailure code [DDB6L4] Parking Brake Signal MalfunctionFailure code [DDD7KA] Failure of Variable Speed ControlFailure code [DDD7KY] Hot Short of Variable Speed ControlFailure code [DDE5MA] Disconnection of Steering Oil Pressure Switch (Emergency Steering Control Switch)Failure code [DDK3KA] FNR SW Input Signal DisconnectionFailure code [DDK3KB] FNR SW Input Signal Short CircuitFailure code [DDK6KA] FNR Lever Input Signal DisconnectionFailure code [DDK6KY] FNR Lever Input Signal Disconnection (Hot Short)Failure code [DDNRLD] Ground Fault of Work Equipment Lock SwitchFailure code [DDS5L6] Low Steering Oil Pressure (Emergency Steering Control)Failure code [DF10KA] Disconnection of Speed Range Input SwitchFailure code [DF10KB] Disconnection of Speed Range Selector Switch (Hot Short)Failure code [DGH1KX] HST Oil Temperature Sensor Short to GroundFailure code [DGR2KB] Ground Fault of Brake Oil Temperature SensorFailure code [DGR2KZ] Failure of Brake Oil Temperature SensorFailure code [DHH1KX] Failure of HST Oil Pressure SensorFailure code [DHH1KY] Hot Short of HST Oil Pressure SensorFailure code [DHPCKX] Failure of Boom Pressure Sensor (Bottom)Failure code [DHPDKX] Failure of Boom Pressure Sensor (Head)Failure code [DHTCL6] HST Oil Filter Clogging Detection FailureFailure code [DJF1KA] Disconnection or Hot Short Circuit of Fuel Level SensorFailure code [DK5DKA] Failure of 3rd Lever Potentiometer Sensor (Main)Failure code [DK5DKY] Hot Short of 3rd Lever Potentiometer Sensor (Main)Failure code [DK5DL8] 3rd Lever Potentiometer Sensor (Main & Sub) DisagreeFailure code [DK5EKA] Failure of 3rd Lever Potentiometer Sensor (Sub)Failure code [DK5EKY] Hot Short of 3rd Lever Potentiometer Sensor (Sub)Failure code [DKA0KX] Failure of Boom Angle SensorFailure code [DLM3KA] Failure of Cooling Fan Speed SensorFailure code [DLM3LC] Ground Fault of Cooling Fan Speed SensorFailure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B)Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A)Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B)Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B)Failure code [DT22KB] Ground Fault of Work Equip. Lock IndicatorFailure code [DV00KY] Hot Short of Alarm BuzzerFailure code [DW26KA] Open Circuit of Motor 2 SolenoidFailure code [DW26KB] Ground Fault of Motor 2 SolenoidFailure code [DW26KY] Hot Short of Motor 2 SolenoidFailure code [DW44KA] Open Circuit of Directional Pressure Selection SolenoidFailure code [DW44KB] Ground Fault of Directional Pressure Selection SolenoidFailure code [DW44KY] Hot Short of Directional Pressure Selection SolenoidFailure code [DX19KA] Disconnection of Motor 1 SolenoidFailure code [DX19KB] Ground Fault of Motor 1 SolenoidFailure code [DX19KY] Hot Short of Motor 1 SolenoidFailure code [DX20KA] Disconnection of Clutch EPC SolenoidFailure code [DX20KB] Ground Fault of Clutch EPC SolenoidFailure code [DX20KY] Hot Short of Clutch EPC SolenoidFailure code [DXH7KA] Disconnection of Reverse SolenoidFailure code [DXH7KB] Ground Fault of Reverse SolenoidFailure code [DXH7KY] Hot Short of Reverse SolenoidFailure code [DXH8KA] Disconnection of Forward SolenoidFailure code [DXH8KB] Ground Fault of Forward SolenoidFailure code [DXH8KY] Hot Short of Forward SolenoidFailure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)Failure code [H2K0KA] Failure of Quick Coupler Lock SignalFailure code [H2K0KY] Hot Short of Quick Coupler Lock SignalFailure code [J141N1] Steering Pump Over RunFailure code [LA00L3] Failure of Fan ReverseFailure code [M100N1] HST Pump Over RunFailure code [M400N1] HST Motor 1 Over Run

Troubleshooting of electrical system (E-mode)E-1 Engine does not startE-2 Manual preheating system does not workE-3 Automatic preheating system does not workE-4 While preheating is working, preheating monitor does not light upE-5 When starting switch is turned to ON position, nothing is displayed on machine monitorE-6 Travel speed is slowE-7 ECSS does not operateE-8 ECSS remains being operatedE-9 Boom kick-out does not work or is not resetE-10 Bucket positioner does not work or is not resetE-11 Boom FLOAT holding does not work or is not resetE-12 Directional selection does not work normallyE-13 Fan does not rotate in reverseE-14 Fan remains in reverse rotation modeE-15 Wipers do not operateE-16 Window washer does not operateE-17 Headlamp, clearance lamp, tail lamp or license-plate lamp does not light up or does not go outE-18 Working lamp does not light up or does not go outE-19 Turn signal and hazard lamp do not light up or do not go outE-20 Stop lamp does not light up or remains lighting upE-21 Backup lamp does not light up or remains lighting upE-22 Backup alarm does not sound or does not stop soundingE-23 Horn does not sound or does not stop soundingE-24 Alarm buzzer does not sound or does not stop soundingE-25 KOMTRAX system does not operate normallyE-26 Fuel gauge does not indicate correct levelE-27 Seat belt caution lamp indication is incorrect

Troubleshooting for hydraulic and mechanical system (H-mode)Information described in troubleshooting table (H-mode)System chart of hydraulic and mechanical systemsFailure mode and cause tableH-1 Machine travels neither forward nor in reverseH-2 Machine does not travel forward (normally travels in reverse)H-3 Machine does not travel in reverse (normally travels forward)H-4 Both forward and reverse travel speeds are lowH-5 Forward travel speed is low (normal when traveling in reverse)H-6 Reverse travel speed is low (normal when traveling forward)H-7 Machine lacks power when traveling both forward and in reverseH-8 Machine lacks power when traveling forward (normal when traveling in reverse)H-9 Machine lacks power when traveling in reverse (normal when traveling forward)H-10 Engine stalls during travel or engine speed drops significantlyH-11 Machine does not turnH-12 Steering wheel is heavy to turnH-13 Machine sways or large shocks are made while machine turnsH-14 Machine turns to either side unintentionally during travelingH-15 Brake does not work or it is weakH-16 Brake is not released or dragsH-17 Parking brake does not work or it is weakH-18 Parking brake is not released or dragsH-19 Boom does not riseH-20 Boom moves slow or lacks lifting forceH-21 Boom rising speed lowers at certain heightH-22 Lift cylinder cannot hold down bucket (bucket rises off ground)H-23 Hydraulic drift of boom is largeH-24 Boom wobbles during operationH-25 Bucket does not tilt backH-26 Bucket moves slow or lacks tilting back forceH-27 Bucket speed lowers in tilt-back motionH-28 Bucket cylinder cannot hold down bucket (bucket rises off ground)H-29 Hydraulic drift of bucket is largeH-30 Loaded bucket wobbles during travel (with work equipment valve at "HOLD")H-31 Boom and bucket control levers do not move smoothly and are heavy to moveH-32 Engine speed lowers remarkably or engine stalls while work equipment is operatedH-33 Large shock is made when work equipment starts and stopsH-34 When certain work equipment is relieved hydraulically, other work equipment movesH-35 ECSS does not operate and machine pitches and boundsH-36 Fan speed is abnormal (too high or low, or fan does not rotate)H-37 Unusual noise is heard from around fan

Troubleshooting of engine (S-mode)Information mentioned in troubleshooting table (S mode)S-1 Engine does not crank when starting switch is turned to START positionS-2 Engine cranks but no exhaust smoke comes outS-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)S-4 Engine startability is poorS-5 Engine does not pick up smoothlyS-6 Engine stops during operationS-7 Engine runs rough or is unstableS-8 Engine lacks powerS-9 Exhaust smoke is blackS-10 Engine oil consumption is excessiveS-11 Oil becomes contaminated quicklyS-12 Fuel consumption is excessiveS-13 Oil is in coolant (or coolant spurts or coolant level goes down)S-14 Oil pressure dropsS-15 Fuel mixes into engine oilS-16 Water mixes into engine oil (milky)S-17 Coolant temperature rises too high (overheating)S-18 Unusual noise is heardS-19 Vibration is excessiveS-20 Air cannot be bled from fuel circuit

50 Disassembly and assemblyGeneral information on disassembly and assemblyHow to read this manualCoating materials listSpecial tool listSketches of special tools

Engine and cooling systemRemoval and installation of fuel supply pump assemblyRemoval and installation of fuel injector assemblyRemoval and installation of engine hood assemblyRemoval and installation of cylinder head assemblyRemoval and installation of radiator assemblyRemoval and installation of air aftercooler assemblyRemoval and installation of hydraulic oil cooler assemblyRemoval and installation of engine assemblyRemoval and installation of belt for alternator and air conditioner compressorRemoval and installation of engine front oil seal assemblyRemoval and installation of engine rear oil seal assemblyRemoval and installation of cooling fan and fan motor assemblyRemoval and installation of fuel tank assemblyRemoval and installation of KCCV ventilator assemblyRemoval and installation of KDOC mufflerRemoval and installation of EGR cooler assemblyRemoval and installation of EGR valve assembly

Power trainRemoval and installation of transfer assemblyDisassembly and assembly of transfer assemblyRemoval and installation of parking brake assemblyRemoval and installation of parking brake cylinder assemblyDisassembly and assembly of parking brake assemblyRemoval and installation of front axle assemblyRemoval and installation of rear axle assemblyDisassembly and assembly of axle housing assemblyDisassembly and assembly of differential assembly

Undercarriage and frameRemoval and installation of center hinge pinRemoval and installation of counterweight assembly

Hydraulic systemRemoval and installation of HST pump and quadruple type gear pump assemblyRemoval and installation of HST motor 1 assemblyRemoval and installation of HST motor 2 assemblyRemoval and installation of work equipment control valve assemblyRemoval and installation of ECSS (Electronically Controlled Suspension System) valve assemblyRemoval and installation of hydraulic tank assemblyDisassembly and assembly of hydraulic cylinder assembly

Work equipmentRemoval and installation of work equipment assembly

Cab and its attachmentsRemoval and installation of operator's cab and floor frame assemblyRemoval and installation of operator's cab glass (adhered glass)Disassembly and assembly of operator's seatRemoval and installation of air conditioner unit assemblyRemoval and installation of air conditioner compressor assembly

Electrical systemRemoval and installation of machine monitorRemoval and installation of engine controller assemblyRemoval and installation of HST controller assemblyRemoval and installation of KOMTRAX terminal assembly

60 Maintenance standardEngine and cooling systemEngine mount and transfer mountDamperCooling systemCooling fan motor

Power trainDrive shaftTransferAxleDifferentialLimited slip differentialFinal drive

Steering systemOrbitrol valveSteering cylinderSteering columnPriority valveEmergency steering valve

Brake systemCharge valveSlack adjusterBrakeParking brake

Undercarriage and frameAxle mount and center hinge pin

Hydraulic systemHydraulic tankWork equipment control valvePPC valveECSS valveQuadruple gear pump

Work equipmentWork equipment linkageBucketBucket positioner and boom kick-outWork equipment cylinder

80 AppendixAir conditionerPrecautions for refrigerantAir conditioner componentConfiguration and function of refrigeration cycleOutline of refrigeration cycleAir conditioner unitFunctions of main components in air conditioner unitBlower and intake unitCompressorCondenserReceiver drierAir conditioner control panelProcedure for troubleshootingCircuit diagram and arrangement of connector pinsSystem diagramDetails of air conditioner unitParts and connectors layoutInspection by self-diagnosis function (displays diagnosis on the control panel)Testing temperature control systemTesting FRESH/RECIRC air changeoverTesting evaporator temperature sensorTesting relaysTroubleshooting chart 1Troubleshooting chart 2Information described in troubleshooting tableTroubleshooting for power supply system (Air conditioner does not operate)Troubleshooting for compressor and refrigerant system (Air is not cooled)Troubleshooting for blower motor system (No air comes out or air flow is abnormal)Troubleshooting for temperature controlTroubleshooting for FRESH/RECIRC air changeoverConnection of service toolTroubleshooting by gauge pressurePrecautions for disconnecting and connecting hoses and tubes in air conditioner circuitHandling of compressor oil

90 Diagrams and drawingsHydraulic diagrams and drawingsSymbols used in hydraulic circuit diagramsHydraulic circuit diagram

Electrical diagrams and drawingsSymbols used in electric circuit diagramsElectrical circuit diagram

Index